John Deere Radial Piston Pumps ctm7 Technical Manual - PDF DOWNLOAD

Radial Piston Pumps

John Deere Waterloo Works CTM7 (28FEB97) LITHO IN U.S.A.

ENGLISH

Introduction FOREWORD This manual is written for an experienced technician.

Essential tools required in performing certain service work are identified in this manual and are recommended for use.

Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.

This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury.

Use this component technical manual in conjunction with the machine technical manual. An application listing in the introduction identifies productmodel/component type-model relationship. See the machine technical manual for information on component removal and installation, and gaining access to the components.

This manual is divided in two parts: repair and operation and tests. Repair sections contain necessary instructions to repair the component.

Operation and tests sections help you identify the majority of routine failures quickly.

Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values.

Component Technical Manuals are concise service guides for specific components. Component technical manuals are written as stand-alone manuals covering multiple machine applications.

Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes.

MANUAL ORGANIZATION

GROUP GROUP GROUP GROUP GROUP

05—SAFETY 10—GENERAL 15—1000 SERIES PUMPS - REPAIR 20—2000 SERIES PUMPS - REPAIR 25—3000 SERIES PUMPS - REPAIR

GROUP GROUP GROUP GROUP GROUP

30—AUXILIARY CHARGE PUMPS 99—DEALER FABRICATED TOOLS 105—1000 SERIES PUMPS - OPERATION AND TESTS 110—2000 SERIES PUMPS - OPERATION AND TESTS 115—3000 SERIES PUMPS - OPERATION AND TESTS

RX,CTM7,IFC

CTM7 (28FEB97)

-19-17FEB97

Radial Piston Pumps 280297

PN=2

Contents Page

Page

05 Group 05—Safety . . . . . . . . . . . . . . . . . . -05-1 Group 10—General Non-Serialized Hydraulic Pumps . . .

Pump Displacement . . . . . . . . . . .

Hydraulic Pump Serial Number Plate 1000 and 2000 Series (PR) . . . .

3000 Series (HPR) . . . . . . . . . .

Pump Specifications (Basic) 1000 Series . . . . . . . . . . . . . . .

2000 Series . . . . . . . . . . . . . . .

3000 Series . . . . . . . . . . . . . . .

Application Charts Agricultural Equipment . . . . . . . .

Industrial Equipment . . . . . . . . .

OEM . . . . . . . . . . . . . . . . . . . .

Torque Charts . . . . . . . . . . . . . . .

Group 20—2000 Series (PR) Hydraulic Pump Essential or Recommended Tools . . . . . . . . -20-1 Service Equipment and Tools . . . . . . . . . . . -20-2 Specifications . . . . . . . . . . . . . . . . . . . . . -20-3 Pressure Compensator Specifications Standard . . . . . . . . . . . . . . . . . . . . . . . -20-5 Through-Drive . . . . . . . . . . . . . . . . . . . -20-6 Diagnosing Malfunctions . . . . . . . . . . . . . . -20-7 Cross-Sectional and Exploded Views Single Bank Pump . . . . . . . . . . . . . . . . -20-8 Pressure Compensator—Standard Drive. . . -20-9 Pressure Compensator—Through Drive . . -20-10 Double Bank Pump . . . . . . . . . . . . . . . -20-11 Pressure Compensator . . . . . . . . . . . . . -20-12 Piston Assemblies . . . . . . . . . . . . . . . . . -20-13 Check Shaft End Play . . . . . . . . . . . . . . . -20-14 Discharge Valves and Seats . . . . . . . . . . -20-15 Pump Shaft . . . . . . . . . . . . . . . . . . . . . . -20-18 Pump Housing . . . . . . . . . . . . . . . . . . . . -20-25 Bearing Cups . . . . . . . . . . . . . . . . . . . . -20-26 Shaft Seals . . . . . . . . . . . . . . . . . . . . . . -20-27 Inlet Valves . . . . . . . . . . . . . . . . . . . . . . -20-29 Pressure Compensator Housing . . . . . . . . -20-30 Pressure Compensator Valve Standard and Auxiliary Gear Drive Pumps . . . . . . . . . . . . . . . . . . . . . . -20-33 Through Drive Pump . . . . . . . . . . . . . . -20-35 Crankcase Outlet Valve Non-Serialized Pumps . . . . . . . . . . . . . -20-37 Serialized Pumps . . . . . . . . . . . . . . . . -20-41 Fixed Orifice Non-Serialized Pumps . . . . . . . . . . . . . -20-42 Serialized Pumps . . . . . . . . . . . . . . . . -20-42

. . . . . . -10-1 . . . . . . -10-1 . . . . . . -10-4 . . . . . . -10-5 . . . . . . -10-6 . . . . . . -10-7 . . . . . . -10-8 . . . .

. . . .

. . . .

. . . .

. . . .

. -10-9 -10-12 -10-15 -10-16

Group 15—1000 Series (PR) Hydraulic Pump Essential or Recommended Tools . . . . . . . . -15-1 Service Equipment and Tools . . . . . . . . . . . -15-2 Specifications . . . . . . . . . . . . . . . . . . . . . -15-3 Diagnosing Malfunctions . . . . . . . . . . . . . . -15-4 Cross-Sectional and Exploded View . . . . . . -15-5 Piston Assemblies . . . . . . . . . . . . . . . . . . -15-6 Check Shaft End Play . . . . . . . . . . . . . . . . -15-7 Pump Cover . . . . . . . . . . . . . . . . . . . . . . -15-8 Pump Shaft Remove and Install . . . . . . . . . . . . . . . . -15-8 Disassemble and Inspect . . . . . . . . . . . . -15-9 Assemble . . . . . . . . . . . . . . . . . . . . . -15-11 Pump Housing . . . . . . . . . . . . . . . . . . . . -15-11 Bearings . . . . . . . . . . . . . . . . . . . . . . . . -15-12 Shaft and Quad-Ring Seals . . . . . . . . . . . -15-12 Inlet Valves . . . . . . . . . . . . . . . . . . . . . . -15-13 Discharge Valves and Seats . . . . . . . . . . -15-14 Crankcase Outlet Valve Crankcase Outlet Valve . . . . . . . . . . . . . . -15-15 Filter . . . . . . . . . . . . . . . . . . . . . . . . . . -15-16 Pressure Compensator Valve . . . . . . . . . . -15-16

Group 25—3000 Series (HPR) Hydraulic Pump Essential or Recommended Tools . . . . . . . . -25-1 Service Equipment and Tools . . . . . . . . . . . -25-2 Specifications . . . . . . . . . . . . . . . . . . . . . -25-3 Diagnosing Malfunctions . . . . . . . . . . . . . . -25-8

10

15

20

25

30

99

105

Continued on next page

All information, illustrations and specifications in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice.

110

CTM7-19-28FEB97 COPYRIGHT© 1997 DEERE & COMPANY Moline, Illinois All rights reserved A John Deere ILLUSTRUCTION® Manual Previous Editions Copyright 1989, 1988 Deere & Company

CTM7 (28FEB97)

i

115

Radial Piston Pumps 280297

PN=155

Contents

Page

Page

05

10

15

20

25

30

99

105

110

115

Cross-Sectional and Exploded Views Single Bank Pump . . . . . . . . . . . .

Double Bank Pump . . . . . . . . . . . .

Control Valve—Non-Unitized . . . . . .

Control Valve—Unitized . . . . . . . . .

Piston Assemblies . . . . . . . . . . . . . .

Check Shaft End Play . . . . . . . . . . . .

Pump Shaft Remove and Install . . . . . . . . . . . .

Disassemble and Inspect . . . . . . . .

Assemble . . . . . . . . . . . . . . . . . .

Bearing Cups . . . . . . . . . . . . . . . . .

Pump Housing . . . . . . . . . . . . . . . . .

Shaft Seals . . . . . . . . . . . . . . . . . . .

Discharge Valves and Seats . . . . . . .

Inlet Valves . . . . . . . . . . . . . . . . . . .

Inlet Housing . . . . . . . . . . . . . . . . . .

Pressure Compensator Valve—Non-Unitized . . . . . . . . . . .

Manual Destroke—Electric Destroke . .

Pressure Compensator Valve—Unitized

. . . . . .

. . . . . .

. . . . . .

. -25-9 -25-10 -25-11 -25-12 -25-14 -25-15

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

-25-16 -25-18 -25-21 -25-23 -25-23 -25-23 -25-25 -25-26 -25-27

Pressure Compensator Operation Non-Unitized Design . . . . . . .

Unitized Design . . . . . . . . . .

Load Sense Operation Unitized Design . . . . . . . . . .

Adjust Deadhead Pressure . . . .

. . . . . . . -115-4 . . . . . . . -115-8 . . . . . . -115-10 . . . . . . -115-12

Index

. . . -25-29 . . . -25-34 . . . -25-34

Group 30—Auxiliary Charge Pump-2000 and 3000 Series Essential or Recommended Tools . . . . . . . . -30-1 Specifications . . . . . . . . . . . . . . . . . . . . . -30-1 Auxiliary Charge Pump Disassemble and Inspect . . . . . . . . . . . . -30-2 Assemble . . . . . . . . . . . . . . . . . . . . . . -30-4 Group 99—Dealer Fabricated Tools Group 105—1000 Series (PR)-Operation and Tests How Hydraulic Lines Are Routed . . . . . . . -105-1 Pump Operation . . . . . . . . . . . . . . . . . . -105-2 Adjust Deadhead Pressure . . . . . . . . . . . -105-4 Group 110—2000 Series (PR)-Operation and Tests How Hydraulic Lines Are Routed . . . . . . . -110-1 Pump Operation . . . . . . . . . . . . . . . . . . -110-2 Pressure Compensator Valve Operation . . . -110-3 Adjust Deadhead Pressure . . . . . . . . . . . -110-5 Group 115—3000 Series (HPR)-Operation and Tests How Hydraulic Lines Are Routed . . . . . . . -115-1 Pump Operation . . . . . . . . . . . . . . . . . . -115-2 CTM7 (28FEB97)

ii

Radial Piston Pumps 280297

PN=156

Contents

INDX

CTM7 (28FEB97)

iii

Radial Piston Pumps 280297

PN=157

Contents

INDX

CTM7 (28FEB97)

iv

Radial Piston Pumps 280297

PN=158

Group 05

Safety RECOGNIZE SAFETY INFORMATION This is the safety-alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury.

-UN-07DEC88

05 1

T81389

Follow recommended precautions and safe operating practices.

DX,ALERT

-19-03MAR93

DX,FIRE2

-19-03MAR93

DX,FLUID

-19-03MAR93

PREPARE FOR EMERGENCIES Be prepared if a fire starts.

-UN-23AUG88

Keep a first aid kit and fire extinguisher handy.

TS291

Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.

AVOID HIGH-PRESSURE FLUIDS

-UN-23AUG88

Escaping fluid under pressure can penetrate the skin causing serious injury.

Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.

X9811

Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids.

If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A.

CTM7 (28FEB97)

-05-1

Radial Piston Pumps 280297

PN=3

Safety

WEAR PROTECTIVE CLOTHING

-UN-23AUG88

Wear close fitting clothing and safety equipment appropriate to the job.

Prolonged exposure to loud noise can cause impairment or loss of hearing.

TS206

Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises.

Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine.

DX,WEAR

-19-10SEP90

DX,CLEAN

-19-04JUN90

DX,LOOSE

-19-04JUN90

WORK IN CLEAN AREA

T6642EJ

-UN-18OCT88

Before starting a job: • Clean work area and machine.

• Make sure you have all necessary tools to do your job.

• Have the right parts on hand.

• Read all instructions thoroughly; do not attempt shortcuts.

SERVICE MACHINES SAFELY

-UN-23AUG88

Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result.

Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts.

TS228

05 2

CTM7 (28FEB97)

-05-2

Radial Piston Pumps 280297

PN=4

Safety

ILLUMINATE WORK AREA SAFELY Illuminate your work area adequately but safely. Use a portable safety light for working inside or under the machine. Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel or oil.

TS223

-UN-23AUG88

05 3

DX,LIGHT

-19-04JUN90

DX,LIFT

-19-04JUN90

DX,TORCH

-19-03MAR93

USE PROPER LIFTING EQUIPMENT

-UN-23AUG88

Lifting heavy components incorrectly can cause severe injury or machine damage.

TS226

Follow recommended procedure for removal and installation of components in the manual.

AVOID HEATING NEAR PRESSURIZED FLUID LINES

TS953

-UN-15MAY90

Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials. Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area.

CTM7 (28FEB97)

-05-3

Radial Piston Pumps 280297

PN=5

Safety

USE PROPER TOOLS

-UN-08NOV89

Use tools appropriate to the work. Makeshift tools and procedures can create safety hazards.

Use power tools only to loosen threaded parts and fasteners.

TS779

For loosening and tightening hardware, use the correct size tools. DO NOT use U.S. measurement tools on metric fasteners. Avoid bodily injury caused by slipping wrenches.

Use only service parts meeting John Deere specifications.

DX,REPAIR

-19-04JUN90

DX,DRAIN

-19-03MAR93

DISPOSE OF WASTE PROPERLY

-UN-26NOV90

Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with John Deere equipment include such items as oil, fuel, coolant, brake fluid, filters, and batteries.

Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.

TS1133

05 4

Do not pour waste onto the ground, down a drain, or into any water source.

Air conditioning refrigerants escaping into the air can damage the Earth’s atmosphere. Government regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants.

Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your John Deere dealer.

CTM7 (28FEB97)

-05-4

Radial Piston Pumps 280297

PN=6

Safety

LIVE WITH SAFETY Before returning machine to customer, make sure machine is functioning properly, especially the safety systems. Install all guards and shields.

TS231

-19-07OCT88

05 5

DX,LIVE

CTM7 (28FEB97)

-05-5

-19-25SEP92

Radial Piston Pumps 280297

PN=7

Safety

05 6

CTM7 (28FEB97)

-05-6

Radial Piston Pumps 280297

PN=8

Group 10

General NON-SERIALIZED HYDRAULIC PUMPS— 1000 AND 2000 SERIES (PR)

10 1

R39691

-UN-22JAN90

Some 1000 and 2000 Series pumps will not have a serial number plate. A model number (A) will be stamped on the hub of the pump housing. This will aid in pump identification, however, design changes for non-serialized pumps are usually tied to the application or vehicle serial number.

Non-serialized and serialized 1000 Series pumps have different model numbers, however, the designs are the same.

Non-serialized 2000 Series pumps have different designed pressure compensator valves (stroke control valves) and pump shaft rotary assemblies than serialized pumps. Although the designs are somewhat different, the function is the same. NON-SERIALIZED and SERIALIZED 2000 Series pump differences will be called out in this technical manual.

All current designed John Deere Radial Piston Hydraulic Pumps have serial number plates.

RX,CTM710,1

-19-17FEB97

RX,CTM710,2

-19-17FEB97

PUMP DISPLACEMENT—1000 SERIES (PR) All 1000 Series four piston pumps have a displacement of 11 cm3 (0.7 in.3) and eight piston versions have a displacement of 23 cm3 (1.4 in.3).

CTM7 (28FEB97)

-10-1

Radial Piston Pumps 280297

PN=9

General/Pump Displacement

PUMP DISPLACEMENT—2000 SERIES (PR)

The pump shaft eccentric cam and piston bore determines the displacement of the pump.

Displacement can be identified by the number of grooves (A) machined at the base of the shaft splines and on single bank pumps by the measured distance (B) between the centering marks on the end of the pump shaft.

-UN-23JAN90 R40148

R40103

-UN-23JAN90

10 2

NOTE: Centering mark measurements are from center-to-center.

SINGLE BANK Grooves (A)

0 2 1 0

Displacement

40 cm3 (2.4 in.3)* 40 cm3 (2.4 in.3)** 50 cm3 (3 in.3) 65 cm3 (4 in.3)

DOUBLE BANK Distance (B) Between Marks 6.5 mm 6.5 mm 8.0 mm 8.7 mm

Grooves (A)

1 0

Displacement

100 cm3 (6 in.3) 130 cm3 (8 in.3)

* Non-Serialized ** Serialized

CTM7 (28FEB97)

RX,CTM710,3

-10-2

-19-17FEB97

Radial Piston Pumps 280297

PN=10

General/Pump Displacement

PUMP DISPLACEMENT— 3000 SERIES (HPR)

10 3

2—40 cm3 (2.4 in.3) 1—52 cm3 (3 in.3) 0—65 cm3 (4 in.3)

DOUBLE BANK

R39693

SINGLE BANK

-UN-22JAN90

The pump shaft eccentric cam controls the displacement of the pump. Displacement can be determined by the number of grooves (A) machined on the shaft at the base of the splines.

1—104 cm3 (6 in.3) 2—115 cm3 (7 in.3) 0—130 cm3 (8 in.3)

RX,CTM710,4

CTM7 (28FEB97)

-10-3

-19-19FEB97

Radial Piston Pumps 280297

PN=11

General/Hydraulic Pump Serial Number Plate

HYDRAULIC PUMP SERIAL NUMBER PLATE—1000 AND 2000 SERIES (PR)

R39942

-19-21APR89

10 4

A—Radial Pump (RP) B—Frame Size C—Displacement (cm3/rev)

D—Ports in Primary (and Secondary) Housings E—Rotation (E)-Either (R)-Right (L)-Left

The serial number plate on a 1000 Series hydraulic pump is located on the top of the pump housing cover. For 2000 Series pumps, the serial number plate is located on the top right side (viewing from

F—Stroke Control Valve Option

G—Not Currently Used

the shaft end). The information on the serial number plate may be used to identify repair information in this component technical manual.

RX,CTM710,5

CTM7 (28FEB97)

-10-4

-19-17FEB97

Radial Piston Pumps 280297

PN=12

General/Hydraulic Pump Serial Number Plate

HYDRAULIC PUMP SERIAL NUMBER PLATE—3000 SERIES (HPR)

R39943

-19-21APR89

10 5

A—Master Machine Code (247) B—Displacement (per rev) 1-40 cm3 (2.4 in.3) 2-52 cm3 (3 in.3) 3-65 cm3 (4 in.3) 4-Not Currently Used 5-104 cm3 (6 in.3) 6-115 cm3 (7 in.3) 7-130 cm3 (8 in.3) C—Manufacturing Unit (R) D—Output Drive 1-None 2-Auxiliary SAE “B” Drive 3-Through Drive 4-Auxiliary Gear Pump 5-Not Currently Used

E—Inlet Port 1-Four Bolt Flange 2-O-Ring Port F—Pressure Setting 1-10 000 kPa (100 bar) (1450 psi) 2-16 000 kPa (160 bar) (2300 psi) 3-17 500 kPa (175 bar) (2550 psi) 4-19 000 kPa (190 bar) (2750 psi) 5-22 500 kPa (225 bar) (3250 psi)

The serial number plate on a 3000 Series pump is located on the top-center of the pump. Pump identity can be determined by the information (configuration code) on the second line of the serial number plate.

G—Control Type 1-Pressure Compensated 2-Not Currently Used 3-Pressure Compensated External Control 4-Load Sense 1035 kPa (10 bar) (150 psi) 5-Load Sense 2070 kPa (20 bar) (300 psi) 6-Load Sense 3005 kPa (30 bar) (450 psi) H—Input Drive 1-SAE “C” Mount 2-John Deere Mount

I—Destroke 1-None 2-Manual 3-Electric (6v) (Normally Closed) 4-Electric (12V) (Normally Closed) 5-Electric (12V) (Normally Open) 6-Electric (24V) (Normally Open)

Some pumps will have a part number stamped on the SECOND LINE of the serial number plate instead of the information shown above.

The information on the serial number plate may be used to identify repair information in this component technical manual.

RX,CTM710,6

CTM7 (28FEB97)

-10-5

-19-17FEB97

Radial Piston Pumps 280297

PN=13

General/Pump Specifications (Basic)

BASIC PUMP SPECIFICATIONS—1000 SERIES

10 6

11 cm3 (0.7 in.3)

23 cm 3 (1.4 in.3)

Number of Pump Housings

1

1

Number of Pistons

4

8

Pump Housing Bore ID

17.28—17.29 mm (0.6802—0.6808 in.)

17.28—17.29 mm (0.6802—0.6808 in.)

Piston OD

17.26—17.27 mm (0.6795—0.6799 in.)

17.26—17.27 mm (0.6795—0.6799 in.)

Rated Speed (rpm)

2500

2500

Rated Flow (gpm)

6.75

13.5

Rated Pressure * at No Flow (psi) at Max Flow (psi)

2750 2000

2750 2000

Overall Dimensions Height (in.)

Width (in.)

Length (in.)

8.70 9.67 9.15

8.70 9.67 **9.15

* See Machine Manual for proper setting ** 11.55 for pump with through drive

CTM7 (28FEB97)

RX,CTM710,7

-10-6

-19-19FEB97

Radial Piston Pumps 280297

PN=14

General/Pump Specifications (Basic)

BASIC PUMP SPECIFICATIONS—2000 SERIES 40 cm3 (2.4 in.3)

50 cm3 (3 in. 3)

Number of Pump Housings

1

1

1

2

2

Number of Pistons

8

8

8

16

16

Pump Housing Bore ID

22.223—22.233 mm (0.8749—0.8753 in.)

22.223—22.233 mm (0.8749—0.8753 in.)

24.483—24.493 mm (0.9639—0.9643 in.)

22.223—22.233 mm (0.8749—0.8753 in.)

24.483—24.493 mm (0.9639—0.9643 in.)

Piston OD

22.200—22.210 mm (0.8740—0.8744 in.)

22.200—22.210 mm (0.8740—0.8744 in.)

24.460—24.470 mm (0.9630—0.9634 in.)

22.200—22.210 mm (0.8740—0.8744 in.)

24.460—24.470 mm (0.9630—0.9634 in.)

Rated Speed (rpm)

2500

2500

2500

2500

2200

Rated Flow (gpm)

23.3

30.2

39.5

64.9

80.0

Rated Pressure * No Flow (psi) Max Flow (psi)

2550 2300

2550 2300

2550 2300

2550 2300

2400 2000

Overall Dimensions Height (in.)

Width (in.)

Length (in.)

9.50 9.66 9.02**

9.50 9.66 9.02***

9.50 9.66 9.02***

9.50 9.66 13.45

9.50 9.66 13.45

65 cm3 (4 in.3)

100 cm3 (6 in.3)

130 cm3 (8 in. 3)

10 7

* See Machine Manual for correct setting ** 12.48 for pump with through drive option *** 11.76 for pump with auxiliary charge pump option

CTM7 (28FEB97)

RX,CTM710,8

-10-7

-19-19FEB97

Radial Piston Pumps 280297

PN=15

General/Pump Specifications (Basic)

BASIC PUMP SPECIFICATIONS—3000 SERIES 40 cm3 (2.4 in.3)

52 cm3 (3 in.3)

65 cm3 (4 in.3)

104 cm3 (6 in.3)

115 cm3 (7 in.3)

130 cm3 (8 in.3)

Number of Pump Housings

1

1

1

2

2

2

Number of Pistons

8

8

8

16

16

16

Pump Housing Bore ID

25.395—25.405 mm (0.9998—01.0001 in.)

same

same

same

same

same

Piston OD

25.363—25.373 mm (0.9985—0.9989 in.)

same

same

same

same

same

Rated Speed (rpm)

3000

3000

2800

3000

2800

2800

Rated Flow (gpm)

34.8

45.3

53.3

90.7

94.2

106.4

Rated Pressure * No Flow (psi) Max Flow (psi)

3250 3000

3250 3000

3250 3000

3250 3000

3250 3000

3250 3000

9.96** 11.32 17.72

9.96** 11.32 17.72

9.96** 11.32 17.72

10 8

Overall Dimensions Height (in.)

Width (in.)

Length (in.)

9.96** 11.32 11.84***

9.96** 11.32 11.84***

9.96** 11.32 11.84***

* See Machine Manual for correct setting ** 9.49 for non-unitized pumps (top line of serial number plate seventh digit from left is a “2”) *** 13.61 for pump with auxiliary SAE “C” through drive shaft 14.58 for pump with auxiliary charge pump option

CTM7 (28FEB97)

-10-8

RX,CTM710,9

-19-19FEB97

Radial Piston Pumps 280297

PN=16

General/Application Charts

PUMP APPLICATION CHART—JOHN DEERE AGRICULTURAL EQUIPMENT Machine Model Number m3 100 cm3 1

1000 Series 11 cm3 23 cm3 30 cm3

2000 Series—Single Bank 40 cm3 50 cm3 65

2000 Series—Double Bank

10 9

Row Crop and Utility Tractors 2510 3010 4010 5010 1020 1520 2020 2520 3020

X X X

X* X X X

X X X

X* X

X

X X X

4000 4020 4320 4520 4620 5020 1530 2030 2630

X X X

4030 4230 4430 4630 6030 2040 2240 2440 2640 2840 2940

X X X X X

X X X X

X X X

X X X X X

X X X X

X X X

X X X X

X X X X

4040 4240 4440 4640 4840

* Replacement pump—original pump is a four piston 2000 series pump

CTM7 (28FEB97)

X X X X X X

-10-9

RX,CTM710,10

-19-19FEB97

Radial Piston Pumps 280297

PN=17

General/Application Charts

Machine Model Number

10 10

1000 Series 11 cm3 23 cm3

2000 Series—Single Bank 40 cm3 50 cm3 65 cm3

2000 Series—Double Bank 100 cm3 130 cm3

Row Crop and Utility Tractors 2150 2155 2255 2350 2355N

X X X X X

2550 2555 2750 2755 2855N

X X X X

2950 2955 3150 3155

X X X X X X X X X X X

4050 4055 4250 4255 4450 4455

X X X X X X

4555 4650 4755 4850 4955

X X X X X

4560 4760 4960

X X X

Four Wheel Drive Tractors 7020 7520 8430 8630

X X X X

8440 8640 8450 8650 8850

X X X X X

RX,CTM710,11

CTM7 (28FEB97)

-10-10

-19-17FEB97

Radial Piston Pumps 280297

PN=18

General/Application Charts

Machine Model No.

1000 Series 11 cm3 23 cm3

2000 Series—Single Bank 40 cm3 50 cm3 65 cm3

2000 Series—Double Bank 100 cm3 130 cm3

10 11

Cotton Picker/Strippers 7440 7445 9920

X X X

9930 9940 9950 9960 9965

X X X

X X X

RX,CTM710,12

Machine Model Number

3000 Series—Single Bank 40 cm3 52 cm3 65 cm3

-19-17FEB97

3000 Series—Double Bank 104 cm3 115 cm3 130 cm3

Four Wheel Drive Tractors 8560 8760 8960

X X X

8570 8770 8870 8970

X X X X

RX,CTM710,13

CTM7 (28FEB97)

-10-11

-19-17FEB97

Radial Piston Pumps 280297

PN=19

General/Application Charts

PUMP APPLICATION CHART—JOHN DEERE INDUSTRIAL EQUIPMENT

10 12

Machine Model Number

1000 Series 11 cm3 23 cm3

2000 Series—Single Bank 40 cm3 50 cm3 65 cm3

2000 Series—Double Bank 100 cm3 130 cm3

Tractors JD300 JD301 301A 302

X X

X X X X

JD400 JD401 401B 401D

X X

X X X X

X

X

X

X

JD500 JD600 JD700A

X X X

Backhoe Loaders 300B 302A 401C JD310 310A

X X X X X

310B 410 410B JD500A JD500B

X X X X X

415B 500C 510 510B 515B 610B 710B

X X X

X X

X X X

RX,CTM710,14

CTM7 (28FEB97)

-10-12

-19-19FEB97

Radial Piston Pumps 280297

PN=20

General/Application Charts

Machine Model Number

1000 Series 11 cm3 23 cm3

2000 Series—Single Bank 40 cm3 50 cm3 65 cm3

2000 Series—Double Bank 100 cm3 130 cm3

10 13

Graders JD570 570A 570B JD670

X X X X

670A 672A 670B 672B

X X X X

X X X X

770 770A 772A 770B 772B

X X X X

X X X X X

X

X

Forestry 340D JD440 JD440A JD440B 440C

X

X X X X X

440D 448D JD540 JD540A 540B

X X X X X

540D 548D 640 640D 648D

X X X X

X

JD740 JD740GS JD740A 740AGS JD743 743A

X

X X

X X X X RX,CTM710,15

CTM7 (28FEB97)

-10-13

-19-11JAN91

Radial Piston Pumps 280297

PN=21

General/Application Charts

Machine Model Number

10 14

1000 Series 11 cm3 23 cm3

2000 Series—Single Bank 40 cm3 50 cm3 65 cm3

2000 Series—Double Bank 100 cm3 130 cm3

Four Wheel Drive Loaders JD444 444C JD544 JD544A

X X X X

JD544B 544C JD644 JD644A

X X X X

JD644B 644C JD646 JD646B 646C

X X X X X

Scrapers JD760 JD760A JD762

X X X

762A 762B 862 862B

X X X X

RX,CTM710,16

Machine Model Number

3000 Series—Single Bank 40 cm3 52 cm3 65 cm3

-19-11JAN91

3000 Series—Double Bank 104 cm3 115 cm3 130 cm3

Backhoe Loaders 410C 510C 610C 710C

X X X

410D 510D 710D

X X

X

X

Forestry 648D

X

RX,CTM710,17

CTM7 (28FEB97)

-10-14

-19-17FEB97

Radial Piston Pumps 280297

PN=22

General/Application Charts

PUMP APPLICATION CHART—OEM Machine Model Number

1000 Series 11 cm3 23 cm3

OEM

2000 Series—Single Bank 40 cm3 50 cm3 65 cm3

X

X

X

2000 Series—Double Bank 100 cm3 130 cm3

X

X

X

RX,CTM710,18

Machine Model Number

OEM

3000 Series—Single Bank 40 cm3 52 cm3 65 cm3

X

X

X

-10-15

-19-19FEB97

3000 Series—Double Bank 104 cm3 115 cm3 130 cm3

X

X

X

RX,CTM710,19

CTM7 (28FEB97)

10 15

-19-11JAN91

Radial Piston Pumps 280297

PN=23

General/Torque Charts

METRIC BOLT AND CAP SCREW TORQUE VALUES

TS1163

-19-04MAR91

10 16

Class 4.8 Size

Lubricateda

Class 8.8 or 9.8 Drya

Lubricateda

Class 10.9

Dry a

N·m

lb-ft

N·m

lb-ft

N·m

lb-ft

N·m

M6 M8 M10

4.8 12 23

3.5 8.5 17

6 15 29

4.5 11 21

9 22 43

6.5 16 32

M12 M14 M16

40 63 100

29 47 73

50 80 125

37 60 92

75 120 190

M18 M20 M22

135 190 260

100 140 190

175 240 330

125 180 250

M24 M27 M30

330 490 675

250 360 490

425 625 850

M33 M36

900 1150

675 850

1150 1450

Lubricateda

Class 12.9 Dry a

Lubricateda

lb-ft

N·m

lb-ft

N·m

lb-ft

N·m

11 28 55

8.5 20 40

13 32 63

9.5 24 47

17 40 80

12 30 60

15 37 75

11.5 28 55

19 47 95

14.5 35 70

55 88 140

95 150 240

70 110 175

110 175 275

80 130 200

140 225 350

105 165 255

130 205 320

95 150 240

165 260 400

120 190 300

260 375 510

195 275 375

330 475 650

250 350 475

375 530 725

275 400 540

475 675 925

350 500 675

440 625 850

325 460 625

560 800 1075

410 580 800

310 450 625

650 950 1300

475 700 950

825 1200 1650

600 875 1200

925 1350 1850

675 1000 1350

1150 1700 2300

850 1250 1700

1075 1600 2150

800 1150 1600

1350 2000 2700

1000 1500 2000

850 1075

1750 2250

1300 1650

2200 2850

1650 2100

2500 3200

1850 2350

3150 4050

2350 3000

2900 3750

2150 2750

3700 4750

2750 3500

DO NOT use these values if a different torque value or tightening procedure is given for a specific application. Torque values listed are for general use only. Check tightness of fasteners periodically.

Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical property class.

lb-ft

Dry a N·m

lb-ft

Make sure fasteners threads are clean and that you properly start thread engagement. This will prevent them from failing when tightening.

Tighten plastic insert or crimped steel-type lock nuts to approximately 50 percent of the dry torque shown in the chart, applied to the nut, not to the bolt head.

Tighten toothed or serrated-type lock nuts to the full torque value.

Fasteners should be replaced with the same or higher property class. If higher property class fasteners are used, these should only be tightened to the strength of the original. a

“Lubricated” means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings. “Dry” means plain or zinc plated without any lubrication.

CTM7 (28FEB97)

-10-16

DX,TORQ2

-19-20JUL94

Radial Piston Pumps 280297

PN=24

General/Torque Charts

UNIFIED INCH BOLT AND CAP SCREW TORQUE VALUES

TS1162

-19-04MAR91

10 17

Grade 2b

Grade 1 Size

Lubricateda

Drya

Lubricateda

Grade 5, 5.1, or 5.2 Dry a

Lubricateda

Grade 8 or 8.2

Dry a

Lubricateda

Dry a

N·m

lb-ft

N·m

lb-ft

N·m

lb-ft

N·m

lb-ft

N·m

lb-ft

N·m

lb-ft

N·m

lb-ft

N·m

lb-ft

1/4 5/16 3/8

3.7 7.7 14

2.8 5.5 10

4.7 10 17

3.5 7 13

6 12 22

4.5 9 16

7.5 15 27

5.5 11 20

9.5 20 35

7 15 26

12 25 44

9 18 33

13.5 28 50

10 21 36

17 35 63

12.5 26 46

7/16 1/2 9/16

22 33 48

16 25 36

28 42 60

20 31 45

35 53 75

26 39 56

44 67 95

32 50 70

55 85 125

41 63 90

70 110 155

52 80 115

80 120 175

58 90 130

100 150 225

75 115 160

5/8 3/4 7/8

67 120 190

50 87 140

85 150 240

62 110 175

105 190 190

78 140 140

135 240 240

100 175 175

170 300 490

125 225 360

215 375 625

160 280 450

240 425 700

175 310 500

300 550 875

225 400 650

1 1-1/8 1-1/4

290 400 570

210 300 425

360 510 725

270 375 530

290 400 570

210 300 425

360 510 725

270 375 530

725 900 1300

540 675 950

925 1150 1650

675 850 1200

1050 1450 2050

750 1075 1500

1300 1850 2600

975 1350 1950

1-3/8 1-1/2

750 1000

550 725

950 1250

700 925

750 990

550 725

950 1250

700 930

1700 2250

1250 1650

2150 2850

1550 2100

2700 3600

2000 2650

3400 4550

2550 3350

DO NOT use these values if a different torque value or tightening procedure is given for a specific application. Torque values listed are for general use only. Check tightness of fasteners periodically.

Fasteners should be replaced with the same or higher grade. If higher grade fasteners are used, these should only be tightened to the strength of the original.

Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade.

Make sure fasteners threads are clean and that you properly start thread engagement. This will prevent them from failing when tightening.

a

“Lubricated” means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings. “Dry” means plain or zinc plated without any lubrication.

Tighten plastic insert or crimped steel-type lock nuts to approximately 50 percent of the dry torque shown in the chart, applied to the nut, not to the bolt head.

Tighten toothed or serrated-type lock nuts to the full torque value.

b

Grade 2 applies for hex cap screws (not hex bolts) up to 152 mm (6-in.) long. Grade 1 applies for hex cap screws over 152 mm (6-in.) long, and for all other types of bolts and screws of any length.

CTM7 (28FEB97)

-10-17

DX,TORQ1

-19-20JUL94

Radial Piston Pumps 280297

PN=25

General/Torque Charts

10 18

CTM7 (28FEB97)

-10-18

Radial Piston Pumps 280297

PN=26

Group 15

1000 Series (PR) Hydraulic Pump ESSENTIAL OR RECOMMENDED TOOLS NOTE: Order tools from the U.S. SERVICE-GARD™ or European Microfiche Tool Catalogs.

RECOMMENDED TOOLS, as noted, are suggested to perform the job correctly. Some tools may be available from local suppliers or may be fabricated.

15 1

ESSENTIAL TOOLS listed are required to perform the job correctly and are obtainable only from SERVICE-GARD or European Tool Catalogs.

RX,TOOLS RW25125

-19-21APR94

-UN-14APR94

Bench-Mounted Holding Fixture . . . . . . . . . D01006AA* Hold components during disassembly and assembly * RECOMMENDED TOOL RW40022

RX,D01006AA

-19-25NOV96

RX,D01061AA

-19-17FEB97

RX,JDG127

-19-17FEB97

RX,JDH6

-19-17FEB97

JDH39B

-19-14DEC90

-UN-08SEP93

Blind-Hole Puller Set . . . . . . . . . . . . . . . . D01061AA Remove bearings, bushings, and sleeves from blind holes

RW25636

O-Ring Seal Tool Set . . . . . . . . . . . . . . . .

-UN-19FEB97

JDG127*

Protect machined surfaces when replacing O-rings * RECOMMENDED TOOL RW25637

-UN-19FEB97

O-Ring Seal Hook . . . . . . . . . . . . . . . . . . . . . JDH6* Remove and install O-ring seals * RECOMMENDED TOOL R40104

-UN-23AUG88

Hydraulic Pump Seat Installing Tool Set . . . . . JDH39B Install and remove discharge valve seats

CTM7 (28FEB97)

-15-1

Radial Piston Pumps 280297

PN=27

1000 Series (PR) Hydraulic Pump/Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

15 2

NOTE: Order tools from the U.S. SERVICEGARD™ Catalog or from the European Microfiche Tool Catalog (MTC). Some tools may be available from a local supplier.

Name

Use

JT05714 Hydraulic Pump Parts Tray

Organize, identify, and protect pump parts during repair

RX,CTM715,1

CTM7 (28FEB97)

-15-2

-19-19FEB97

Radial Piston Pumps 280297

PN=28

1000 Series (PR) Hydraulic Pump/Specifications

HYDRAULIC PUMP—1000 SERIES SPECIFICATIONS

15 3

Item

Measurement

Specification

Piston Plug

Torque

122 N·m (90 lb-ft)

Inlet Valve Seats

Torque

68 N·m (50 lb-ft)

Cover-to-Pump Housing

Torque

47 N·m (35 lb-ft)

Standard Drive

End Play

0.152—0.941 mm (0.006—0.037 in.)

Through Drive

End Play

(0.0254—0.0762 mm) (0.001—0.003 in.)

Piston

OD

17.259—17.269 mm (0.6795—0.6799 in.)

Piston Bore

ID

17.277—17.292 mm (0.6802—0.6808 in.)

Piston Spring

Free Length (approximate) Test Length

43 mm (1.9 in.)

32 mm at 80—100 N (1.3 in. at 18—22 lb force)

Discharge Valve Spring

Free Length (approximate) Test Length

12.2 mm (0.5 in.)

7.6 mm at 11—14 N (0.3 in. at 2.5— 3.0 lb force)

Inlet Valve Spring

Free Length (approximate) Test Length

13 mm (0.5 in.)

8 mm at 1.4—1.8 N (0.3 in. at 0.3—0.4 lb force)

Pressure Compensator Valve Spring

Free Length (approximate) Test Length

71 mm (2.8 in.)

63.3 mm at 701—857 N (2.5 in. at 158—193 lb force)

Crankcase Outlet Valve

Free Length (approximate) Test Length

63.5 mm (2.5 in.)

52.5 mm at 196—240 N (2.1 in. at 44—54 lb force)

Pump Shaft:

RX,CTM715,2

CTM7 (28FEB97)

-15-3

-19-19FEB97

Radial Piston Pumps 280297

PN=29

1000 Series (PR) Hydraulic Pump/Diagnosing Malfunctions

DIAGNOSING MALFUNCTIONS

15 4

No Pump Output Broken pump drive shaft Pressure compensator valve malfunction Improper compensator valve adjustment Excessive charge circuit leakage Crankcase outlet valve failure No oil to pump inlet Low Pump Output Low deadhead pressure Compensator valve, seat, or spring failure Worn or scored pistons and bores Broken discharge valve or spring Leaking inlet valve Restricted inlet Insufficient inlet oil Hydraulic Functions Slow Low deadhead pressure Plugged hydraulic filter or return filter Compensator valve, seat, or spring failure Crankcase outlet valve stuck closed Slow Pump Response Weak crankcase outlet valve spring Failure of charge pump or charge leak Plugged return oil filter

Excessive Pump Pressure Improper compensator valve adjustment Function Chatter Insufficient inlet oil (cavitation) Sticking pump pistons Broken discharge valve or spring Broken inlet valve Charge system leakage Charge pump suction air leak Pump and Oil Line Vibration Crankcase outlet valve spring too strong Broken discharge valve or spring Leaking inlet valve Broken inlet valve Pump Shaft Seal Failure Broken discharge valve Over-pressurized seal drain line Pump Noise or Squeal Low deadhead pressure Pressure compensator valve binding Crankcase outlet valve spring too strong Leaking inlet valve Air leak at inlet connections (inspect) Insufficient inlet oil (cavitation)

RX,CTM715,3

CTM7 (28FEB97)

-15-4

-19-17FEB97

Radial Piston Pumps 280297

PN=30

1000 Series (PR) Hydraulic Pump/Cross-Sectional and Exploded View

CROSS-SECTION AND EXPLODED VIEW—1000 SERIES PUMP

R40113

-UN-30NOV88

15 5

1—Pump Housing 2—Piston Plug (8 used) 3—Piston Spring (8 used) 4—Piston (8 used) 5—Cover 6—Crankcase Outlet Valve 7—Orifice Plug 8—Shaft 9—Thrust Washer

10—Race 11—Needle Rollers (33 used) 12—Needle Bearing (2 used) 13—Quad Ring 14—Oil Seal 15—Inlet Valve (8 used) 16—Plug (8 used) 17—Discharge Valve (8 used) 18—Valve Seat (8 used)

19—Adjusting Screw 20—Pressure Compensator Valve Assembly 21—Valve Seat 22—Plug 23—Packing (2 used) 24—Filter 25—Manual Destroke (Optional)

26—Plug 27—Inlet Port (I2) 28—Inlet Port (I1) 29—Crankcase Pressure Port (C1) 30—Discharge Port (S1) 31—Drain Port (D1) 32—Shut-Off Screw Port (E1) RX,CTM715,4

CTM7 (28FEB97)

-15-5

-19-17FEB97

Radial Piston Pumps 280297

PN=31

1000 Series (PR) Hydraulic Pump/Piston Assemblies

REMOVE AND INSPECT PISTON ASSEMBLIES

-UN-23JAN90

IMPORTANT: Pistons must be installed in the original bores if reused. Write numbers on piston plugs, discharge valve plugs and pump housing for identification.

1. Remove piston assemblies and place in a parts tray to insure installation into the same bores from which the assemblies were removed.

R40135

15 6

2. Inspect piston pugs (A) for thread damage.

3. Inspect face and skirt of pistons (C) for metal transfer, galling or scoring. Replace housing and all eight pistons if these conditions exist.

IMPORTANT: All springs must be the same color code.

4. Inspect springs (B). Replace ALL springs as a set if required.

NEW SPRING SPECIFICATION Free Length (approximate) . . . . . . . . . . . . . . . . . . . 48 mm (1.9 in.)

Test Length . . . . . . . . . . . . . . . . . . . . . . . . . 32 mm at 80—100 N (1.3 in. at 18—22 lb force)

RX,CTM715,5

-19-17FEB97

RX,CTM715,6

-19-17FEB97

INSTALL PISTON ASSEMBLIES 1. Install new O-rings and plastic shields on piston plugs.

IMPORTANT: To prevent damage to O-rings and shields, DO NOT use an air-operated wrench to tighten piston plugs; use a torque wrench.

2. Install piston assemblies and tighten piston plugs to 122 N·m (90 lb-ft).

CTM7 (28FEB97)

-15-6

Radial Piston Pumps 280297

PN=32

1000 Series (PR) Hydraulic Pump/Check Shaft End Play

CHECK SHAFT END PLAY 1. Remove piston assemblies. (See Remove and Inspect Piston Assemblies, this group.)

-UN-23JAN90

15 7

NOTE: Use vice grip with curved jaw for better clamping.

R40125

2. Install vice grips as tightly as possible on pump shaft approximately 5/8 in. from pump housing hub.

3. Put a dial indicator base on pump housing. Put indicator contact point on steel ball placed in center of pump shaft.

4. Turn shaft back and forth while pushing down to align bearings inside the pump housing.

RX,CTM715,7

-19-17FEB97

RX,CTM715,8

-19-17FEB97

5. Zero the indicator.

6. Pry upward on vice grips using a long (3/4 in. minimum) box-end wrench noting indicator reading. If end play is more than specification, check thrust washers (on standard drive) or tapered roller bearings (on through drive) for excessive wear. Increase number or size of shims in pump housing on through drive pump if end play is greater than 0.076 mm (0.003 in.).

END PLAY SPECIFICATION 0.152—0.941 mm (0.006—0.037 in.)

Through Drive . . . . . . . . . . . . . . . . . . . . . . . . . 0.025—0.076 mm (0.001—0.003 in.)

R40126

-UN-23JAN90

Standard Drive . . . . . . . . . . . . . . . . . . . . . . . . .

CTM7 (28FEB97)

-15-7

Radial Piston Pumps 280297

PN=33

1000 Series (PR) Hydraulic Pump/Pump Shaft

REMOVE AND INSTALL PUMP COVER 1. Remove cover and discard gasket.

-UN-23JAN90

2. Inspect crankcase orifice (A) to make sure orifice is open.

R40189

IMPORTANT: For THROUGH DRIVE use cover to install bearing cup on end of pump shaft. DO NOT install shims or new oil seal in cover until bearing cup has been installed.

3. Install cover with new gasket making sure crankcase outlet valve in pump housing correctly aligns with hole (B) in cover.

4. Install and tighten cap screws alternately to 47 N·m (35 lb-ft).

RX,CTM715,9

-19-17FEB97

RX,CTM715,10

-19-17FEB97

REMOVE AND INSTALL PUMP SHAFT

-UN-23JAN90

IMPORTANT: Pistons must be installed in the original bores if reused.

1. Remove piston assemblies. (See Remove and Inspect Piston Assemblies, this group.)

2. Remove pump cover and gasket from pump housing.

R40127

15 8

3. Remove crankcase outlet valve (A) from pump housing.

CTM7 (28FEB97)

-15-8

Radial Piston Pumps 280297

PN=34

1000 Series (PR) Hydraulic Pump/Pump Shaft 4. Check for smooth bearing operation by turning shaft in housing. Replace bearings (and bearing cups on through drive shaft) if bearings stick or are noisy. (See Remove and Install Bearings (Standard Drive), this group.)

-UN-21FEB90

15 9

5. Remove pump shaft assembly.

T88609

NOTE: For through drive shaft, tap end of shaft with a hammer to remove bearing cup and shaft assembly from housing. Make sure shaft is supported during removal procedure.

6. Install new quad ring and oil seal in pump housing.

(See Remove and Install Oil and Quad-Ring Seals, this group.)

IMPORTANT: DO NOT install new oil seal in cover for through drive shaft until bearing cup on end of pump shaft has been installed. Cover is used to install bearing cup and seal damage could result during cup installation.

7. Carefully install shaft assembly.

8. Install bearing cup on through drive shaft (See Remove and Install Pump Cover, this group.)

RX,CTM715,11

-19-19FEB97

RX,CTM715,12

-19-17FEB97

DISASSEMBLE AND INSPECT PUMP SHAFT

R40134

-UN-23JAN90

1. Slowly turn race (A) on shaft. Race must turn smoothly. Replace parts as required if assembly is sticking or noisy.

CTM7 (28FEB97)

-15-9

Radial Piston Pumps 280297

PN=35

1000 Series (PR) Hydraulic Pump/Pump Shaft NOTE: For THROUGH DRIVE, remove bearing cones on shaft using a bearing puller.

-UN-23JAN90

2. Disassemble pump shaft.

3. Inspect pump shaft (A). Replace shaft if shaft journal is pitted, scored or discolored. Needle rollers and race should also be replaced.

5. Inspect race (C). Replace race and pistons if race is discolored, pitted, or scored.

R40131

4. Inspect needle rollers (B). Replace ALL needle rollers if any are discolored, pitted, or scratched.

Standard Drive Shaft

6. Inspect thrust washers (D) (and spacers (E) on through drive). Replace as required.

-UN-23JAN90

NEW PART SPECIFICATION Standard Drive . . . . . . . . . . . . . . . . . . . . . . . . .

2.212—2.311 mm (0.087—0.091 in.)

Through Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13—3.23 mm (0.123—0.127 in.)

NOTE: Bearing cones and cups on through drive shaft should be replaced as a set.

7. Inspect bearing cones (F) on through drive shaft.

Replace bearing cone and cup if spacer wear exists on shoulder surface of cone or if rollers are pitted or cage is damaged.

* Through Drive

CTM7 (28FEB97)

R40132

15 10

Through Drive Shaft

A—Pump Shaft B—Needle Rollers (33 used) C—Race D—Thrust Washer (2 used) E—Spacer (2 used) *

F—Bearing Cone (2 used) * G—Bearing Cup (2 used) * H—Shims (as required) *

RX,CTM715,13

-15-10

-19-25FEB97

Radial Piston Pumps 280297

PN=36

1000 Series (PR) Hydraulic Pump/Pump Housing

ASSEMBLE PUMP SHAFT IMPORTANT: DO NOT use grease to hold needle rollers. Doing so can restrain roller movement and cause pump failure.

Use only clean hydraulic oil.

15 11

Thrust washers on standard drive shaft must be installed with flat side against race.

Spacers on through drive shaft must be installed with chamfered ID toward the shaft journal.

1. Assemble shaft using 33 needle rollers (C) between race (D) and shaft journal.

-UN-21FEB90

IMPORTANT: Taper roller bearings on THROUGH DRIVE SHAFT must be pressed onto pump shaft even if shaft has not been disassembled. This assures correct pump shaft end play.

T88610

For THROUGH DRIVE, perform Step 1a.

1a. Install smaller bearing cone on long splined end of shaft and larger bearing cone on short splined end of shaft.

Standard Drive Shaft

R40133

-UN-23JAN90

A—Pump Shaft B—Thrust Washers C—Needle Rollers D—Race E—Spacer *

Through Drive Shaft

* Through Drive

RX,CTM715,14

-19-19FEB97

RX,CTM715,15

-19-19FEB97

INSPECT PUMP HOUSING

-UN-21FEB90

1. Inspect piston bores (B). Replace pump housing and all pistons if scoring exists.

T88613

2. Install each piston (A) into the bore so piston extends approximately 13 mm (0.50 in.) into the crankcase.

Pistons must slide smoothly and have no side play.

Replace pump housing and all pistons if side play exists or if piston sticks in bore.

CTM7 (28FEB97)

-15-11

Radial Piston Pumps 280297

PN=37

1000 Series (PR) Hydraulic Pump/Shaft and Quad-Ring Seals

REMOVE AND INSTALL BEARINGS (STANDARD DRIVE)

T88621

-UN-21FEB90

1. Remove bearing (C) from pump housing (B) and pump cover using blind-hole puller (A) from D01061AA Blind-Hole Puller Set.

RX,CTM715,16

-19-19FEB97

RX,CTM715,17

-19-17FEB97

RX,CTM715,18

-19-21FEB97

T88625

-UN-21FEB90

2. Install bearing into pump housing and cover 0.5 mm (0.02 in.) below finished surface of crankcase using a 1 in. and 1-5/8 in. disk from a bushing, bearing and seal driver set.

REMOVE AND INSTALL SHAFT AND QUAD-RING SEALS

-UN-21FEB90

1. Remove shaft oil seal.

2. Remove and install new quad-ring seal using a JDH6 O-ring Seal Hook.

T88617

IMPORTANT: If shaft on THROUGH DRIVE has been removed, DO NOT install new oil seal in cover until bearing cup on end of pump shaft has been installed. Pump cover is used to install bearing cup.

(See Remove and Install Cover, this group.)

-UN-21FEB90

3. Install new seal with lip (spring side) toward inside of housing using disks from a bushing, bearing and seal driver set.

4. Apply petroleum jelly to lip of quad-ring seal and shaft oil seal for initial lubrication.

T88618

15 12

CTM7 (28FEB97)

-15-12

Radial Piston Pumps 280297

PN=38

1000 Series (PR) Hydraulic Pump/Inlet Valves

REMOVE, INSPECT, AND INSTALL INLET VALVES

15 13 -UN-21FEB90

1. Remove inlet valves from pump housing.

2. Inspect valve seats (B) and balls (C). Replace if necessary.

T88616

3. Inspect spring (A) and guide (D).

NEW SPRING SPECIFICATION Free Length (approximate) . . . . . . . . . . . . . . . . . . . 13 mm (0.5 in.)

Test Length . . . . . . . . . . . . . . . . . . . . . . . . . . 8 mm at 1.4—1.8 N (0.3 in. at 0.3—0.4 lb force)

4. Install new O-rings on valve seats.

5. Install inlet valves. Tighten valve seats to 68 N·m (50 lb-ft).

RX,CTM715,19

CTM7 (28FEB97)

-15-13

-19-17FEB97

Radial Piston Pumps 280297

PN=39

1000 Series (PR) Hydraulic Pump/Discharge Valves and Seats

REMOVE, INSPECT, AND INSTALL DISCHARGE VALVES

-UN-23JAN90

IMPORTANT: Discharge valves must be installed in the original bores.

1. Write numbers on discharge valve plugs and housing for identification.

R40136

2. Remove discharge valves and place in a parts tray to insure installation into the same bores from which valves were removed.

3. Inspect valve guide (A) for fatigue cracks at tabs and radius of legs.

-UN-23JAN90

4. Inspect stop (D).

5. Inspect spring (C). Replace spring if wear is questionable.

R40137

NEW SPRING SPECIFICATION Free Length (approximate) . . . . . . . . . . . . . . . . . . 13.2 mm (0.5 in.)

Test Length . . . . . . . . . . . . . . . . . . . . . . . . . 7.6 mm at 11—14 N (0.3 in. at 2.5—3 lb force)

6. Inspect valve disk (B). Replace valve disk and discharge valve seat if wear is excessive.

7. Install discharge valves into the original bores.

RX,CTM715,20

-19-17FEB97

RX,CTM715,21

-19-17FEB97

INSPECT, REMOVE, AND INSTALL DISCHARGE VALVE SEATS

-UN-23JAN90

1. Wipe discharge valve seats. Access seat through the discharge valve bore. This should be done before visual inspection since oil on valve seat may give impression of seat damage.

2. Visually inspect discharge valve seats for peening or damage.

R40149

15 14

IMPORTANT: Press fit is critical for sealing. DO NOT remove discharge valve seats unless replacement is absolutely necessary.

3. Remove seats using a puller (A) from D01061AA Blind-Hole Puller Set.

CTM7 (28FEB97)

-15-14

Radial Piston Pumps 280297

PN=40

1000 Series (PR) Hydraulic Pump/Crankcase Outlet Valve 4. Install valve seat (A) using a JDH39-1 Installation Tool (C) from JDH39B Hydraulic Pump Seat Installing Tool Set.

15 15

T88626

-UN-21FEB90

T88620

-UN-21FEB90

5. Push on shoulder of seat (A) until seat surface is 29.4—29.9 mm (1.15—1.18 in.) below spot face surface (B).

RX,CTM715,22

-19-17FEB97

RX,CTM715,23

-19-17FEB97

REMOVE, INSPECT, AND INSTALL CRANKCASE OUTLET VALVE

-UN-21FEB90

1. Remove cover and discard gasket.

2. Inspect crankcase outlet valve spring guide (A), spring (B), valve (C), and pin (D). Replace parts as necessary.

T88608

NEW SPRING SPECIFICATION Free Length (approximate) . . . . . . . . . . . . . . . . . . 63.5 mm (2.5 in.)

Test Length . . . . . . . . . . . . . . . . . . . . . . . 52.5 mm at 196—240 N (2.1 in. at 44—54 lb force)

3. Install crankcase outlet valve making sure end of pin (D) fits into blind hole inside cover.

CTM7 (28FEB97)

-15-15

Radial Piston Pumps 280297

PN=41

1000 Series (PR) Hydraulic Pump/Pressure Compensator Valve

REMOVE, INSPECT, AND INSTALL FILTER

-UN-21FEB90

1. Remove plug (C) to remove packings (A) and filter screen (B).

2. Inspect screen for debris or damage. Clean or replace as required.

T88623

3. Install filter screen with new packings (A) and new O-ring on plug (C).

RX,CTM715,24

-19-17FEB97

RX,CTM715,25

-19-17FEB97

REMOVE, INSPECT, AND INSTALL PRESSURE COMPENSATOR VALVE 1. Remove pressure compensator valve assembly.

2. Inspect valve (B). Replace valve (B) and valve seat (A) if uneven wear or damage exists. Use a wooden dowel or brass drift to remove valve seat (A).

3. Inspect valve guide (C), spring (D), adjusting screw (E), and washer (F). Replace as required.

NEW SPRING SPECIFICATION Free Length (approximate) . . . . . . . . . . . . . . . . . . . 71 mm (2.8 in.)

Test Length . . . . . . . . . . . . . . . . . . . . . . . 63.3 mm at 701—857 N (2.5 in. at 158—193 lb force)

-UN-21FEB90

4. Apply clean hydraulic oil to all parts. Replace O-ring on adjusting screw and install pressure compensator valve assembly.

T88624

15 16

CTM7 (28FEB97)

-15-16

Radial Piston Pumps 280297

PN=42

Group 20

2000 Series (PR) Hydraulic Pump ESSENTIAL OR RECOMMENDED TOOLS NOTE: Order tools from the U.S. SERVICE-GARD™ or European Microfiche Tool Catalogs.

RECOMMENDED TOOLS, as noted, are suggested to perform the job correctly. Some tools may be available from local suppliers or may be fabricated.

20 1

ESSENTIAL TOOLS listed are required to perform the job correctly and are obtainable only from SERVICE-GARD or European Tool Catalogs.

RX,TOOLS RW25125

-19-21APR94

-UN-14APR94

Bench-Mounted Holding Fixture . . . . . . . . . D01006AA* Hold components during disassembly and assembly * RECOMMENDED TOOL RW25634

RX,D01006AA

-19-25NOV96

RX,DFRW52A

-19-17FEB97

RX,JDG127

-19-17FEB97

RX,JDG246

-19-14FEB97

RX,JDG493

-19-14FEB97

-UN-14FEB97

Pressure Compensator Valve Tool . . . . . . . . DFRW52* Remove and install pressure compensator valve and sleeve in non-unitized inlet housing

* RECOMMENDED TOOL—See Group 99 for tool fabrication RW25636

O-Ring Seal Tool Set . . . . . . . . . . . . . . . .

-UN-19FEB97

JDG127*

Protect machined surfaces when replacing O-rings * RECOMMENDED TOOL RW18215

Radial Piston Pump Bearing Cup Puller . . . .

-UN-20APR90

JDG246*

Remove bearing cup from pump housing * RECOMMENDED TOOL RW25635

Pump Shaft Seal Sizer . . . . . . . . . . . . . . .

-UN-14FEB97

JDG493*

Install sealing ring in pump shaft * RECOMMENDED TOOL

CTM7 (28FEB97)

-20-1

Radial Piston Pumps 280297

PN=43

2000 Series (PR) Hydraulic Pump/Service Equipment and Tools R40151

-UN-23AUG88

Spline Protector . . . . . . . . . . . . . . . . . . . . . JDG494

20 2

Install pump shaft

RW25637

JDG494

-19-18DEC90

RX,JDH6

-19-17FEB97

JDH19C

-19-11JAN91

RX,JDH32

-19-21FEB97

JDH39B

-19-14DEC90

-UN-19FEB97

O-Ring Seal Hook . . . . . . . . . . . . . . . . . . . . . JDH6* Remove and install O-ring seals * RECOMMENDED TOOL R40152

-UN-23AUG88

Adjusting Tool . . . . . . . . . . . . . . . . . . . . . . JDH19C Adjust crankcase outlet valve (Non-serialized hydraulic pumps)

RW25638

Hydraulic Pump Seal Replacement Set . . . . . .

-UN-21FEB97

JDH32*

Remove and install oil seal without pump disassembly * RECOMMENDED TOOL R40104

-UN-23AUG88

Hydraulic Pump Seat Installing Tool Set . . . . . JDH39B Install and remove discharge valve seats

SERVICE EQUIPMENT AND TOOLS NOTE: Order tools from the U.S. SERVICEGARD™ Catalog or from the European Microfiche Tool Catalog (MTC). Some tools may be available from a local supplier.

Name

Use

JT05714 Hydraulic Pump Parts Tray

Organize, identify, and protect pump parts during repair

RX,CTM715,1

CTM7 (28FEB97)

-20-2

-19-19FEB97

Radial Piston Pumps 280297

PN=44

2000 Series (PR) Hydraulic Pump/Specifications

HYDRAULIC PUMP—2000 SERIES SPECIFICATIONS

20 3

Item

Measurement

Specification

Inlet Valve Plug

Torque

136 N·m (100 lb ft)

Piston Plug (Internal Hex)

Torque

136 N·m (100 lb-ft)

Piston Plug

Torque

185 N·m (135 lb-ft)

Pump Shaft

End Play

0.025—0.100 mm (0.001—0.004 in.)

40 cm3 (2.4 in.3) - 50 cm3 (3 in.3) and 100 cm3 (6 in.3)

OD

22.2001—22.210 mm (0.8740—0.8744 in.)

65 cm3 (4 in.3) - 130 cm3 (8 in.3)

OD

24.460—24.470 mm (0.9630—0.9634 in.)

40 cm3 (2.4 in.3) - 50 cm3 (3 in.3) and 100 cm3 (6 in.3)

ID

22.223—22.233 mm (0.8749—0.8753 in.)

65 cm3 (4 in.3) - 130 cm3 (8 in.3)

ID

24.483—24.493 mm (0.9639—0.9643 in.)

Lift

2.0—3.0 mm (0.078—0.120 in.)

Free Length (approximate) Test Length

62 mm (2.4 in.)

41.1 mm at 151—178 N (1.6 in. at 34—40 lb force)

Free Length (approximate) Test Length

69.5 mm (2.7 in.)

45.2 mm at 209—236 N (1.8 in. at 47—53 lb force)

Piston:

Piston Bore:

Inlet Valve

Piston Spring: 40 cm3 (2.4 in.3) - 50 cm3 (3 in.3) and 100 cm3 (6 in.3)

65 cm3 (4 in.3) - 130 cm3 (8 in.3)

Single Spring Design

Continued on next page

CTM7 (28FEB97)

-20-3

Radial Piston Pumps 280297

PN=45

2000 Series (PR) Hydraulic Pump/Specifications

Item

20 4

Measurement

Specification

Outer Piston Spring

Free Length (approximate) Test Length

70 mm (2.8 in.)

45.2 mm at 129—156 N (1.8 in. at 29—35 lb force)

Inner Piston Spring

Free Length (approximate) Test Length

69.5 mm (2.7 in.)

45.2 mm at 76—93 N (1.8 in. at 17—21 lb force)

Single Bank Early Design

Free Length (approximate) Test Length

13.5 mm (0.5 in.)

12 mm at 6—7 N (0.5 in. at 1.4—1.7 lb force)

Single Bank Current Design and Non-Serialized Double Bank

Free Length (approximate) Test Length

12.2 mm (0.48 in.)

7.6 mm at 11—14 N (0.3 in. at 2.5—3 lb force)

Serialized Double Bank

Free Length (approximate) Test Length

40.6 mm (1.6 in.)

29.7 mm at 39—48 N (1.2 in. at 9—11 lb force)

Piston Spring: 65 cm3 (4 in.3) - 130 cm3 (8 in.3)

Double Spring Design

Discharge Valve Spring:

RX,CTM720,1

CTM7 (28FEB97)

-20-4

-19-20FEB97

Radial Piston Pumps 280297

PN=46

2000 Series (PR) Hydraulic Pump/Pressure Compensator Specifications

STANDARD PRESSURE COMPENSATOR—2000 SERIES SPECIFICATIONS

20 5

Item

Measurement

Specification

Compensator Valve Housing-to-Pump

Torque

115 N·m (85 lb-ft)

Test Port Plug

Torque

34 N·m (25 lb-ft)

Destroke Port Plug

Torque

61 N·m (45 lb-ft)

Electric Destroke Solenoid Valve

Torque

34 N·m (25 lb-ft)

Long Guide

OD

23.595—23.645 mm (0.9289—0.9309 in.)

Short Guide

OD

19.1 mm (0.75 in.)

Used with long spring guide

Free Length (approximate) Test Length

92 mm (3.6 in.)

84 mm at 556—690 N (3.3 in. at 125—155 lb force)

Used with short spring guide

Free Length (approximate) Test Length

90 mm (3.5 in.)

75 mm at 801—979 N (3.0 in. at 180—220 lb force)

Non-Serialized Pump

Free Length (approximate) Test Length

73.5 mm (2.9 in.)

56 mm at 200—245 N (2.2 in. at 45—55 lb force)

Serialized Pump

Free Length (approximate) Test Length

87 m (3.4 in.)

74.5 mm at 63—77 N (3.0 in. at 14—17 lb force)

Compensator Valve Spring Guide:

Compensator Valve Spring:

Crankcase Outlet Valve Spring:

RX,CTM720,2

CTM7 (28FEB97)

-20-5

-19-20FEB97

Radial Piston Pumps 280297

PN=47

2000 Series (PR) Hydraulic Pump/Pressure Compensator Specifications

THROUGH-DRIVE PRESSURE COMPENSATOR—2000 SERIES SPECIFICATIONS

20 6

Item

Measurement

Specification

Compensator Valve Housing-to-Pump

Torque

115 N·m (85 lb-ft)

Test Port Plug

Torque

34 N·m (25 lb-ft)

Destroke Port Plug

Torque

61 N·m (45 lb-ft)

Electric Destroke Solenoid Valve

Torque

34 N·m (25 lb-ft)

Compensator Valve Dampening Spring

Free Length (approximate) Test Length

20.6 mm (0.8 in.)

13.7 mm at 200—247 N (0.5 in. at 45—55 lb force)

Outer Spring

Free Length (approximate) Test Length

97 mm (3.8 in.)

78 mm at 1340—1640 N (3.1 in. at 300—370 lb force)

Inner Spring

Free Length (approximate) Test Length

92 mm (3.6 in.)

79 m at 495—605 N (3.1 in. at 110—135 lb force)

Compensator Valve Spring:

RX,CTM720,3

CTM7 (28FEB97)

-20-6

-19-17FEB97

Radial Piston Pumps 280297

PN=48

2000 Series (PR) Hydraulic Pump/Diagnosing Malfunctions

DIAGNOSING MALFUNCTIONS No Pump Output Broken pump drive shaft Compensator valve malfunction Improper stroke control valve adjustment Excessive charge circuit leakage Crankcase outlet valve failure Low Pump Output Low deadhead pressure Compressor valve, seat, spring, or packing failure Worn or scored pistons and bores Broken discharge valve or spring Restricted inlet Insufficient inlet oil Hydraulic Functions Slow Low deadhead pressure Plugged hydraulic filter or return filter Compensator valve, seat, spring, or packing failure Crankcase outlet valve stuck closed Slow Pump Response Weak crankcase outlet valve spring Failure of charge pump or charge leak Plugged return oil filter

Function Chatter Insufficient inlet oil (cavitation) Sticking pump pistons Broken discharge valve or spring Broken inlet valve Charge system leakage Charge pump suction air leak

20 7

Pump and Oil Line Vibration Crankcase outlet valve spring too strong Broken discharge valve or spring Leaking inlet valve Broken inlet valve Pump Shaft Seal Failure Broken discharge valve Over-pressurized seal drain line Pump Noise or Squeal Low deadhead pressure Compensator valve, seat, spring, or packing failure Crankcase outlet valve spring too strong Leaking inlet valve Air leak at inlet connections (inspect) Insufficient inlet oil (cavitation)

Excessive Pump Pressure Improper compensator valve adjustment

RX,CTM720,4

CTM7 (28FEB97)

-20-7

-19-17FEB97

Radial Piston Pumps 280297

PN=49

2000 Series (PR) Hydraulic Pump/Cross-Sectional and Exploded Views

CROSS-SECTION AND EXPLODED VIEW—SINGLE BANK PUMP

R40155

-UN-30NOV88

20 8

1—Pump Housing 2—Piston Plug (8 used) 3—Piston Spring (8 or 16 used) 4—Piston (8 used) 5—Discharge Valve (8 used) 6—Shims (as required)

7—Bearing Cup (2 used) 8—Shaft 9—Bearing Cone (2 used) 10—Spacer (2 used) 11—Thrust Washer (2 used) 12—Race 13—Needle Rollers (25 or 50 used)

14—Spacer (3 used) * 15—Sealing Ring 16—Inlet Valve Plug (8 used) 17—Inlet Valve (8 used) 18—Discharge Valve Seat (8 used) 19—Snap Ring

20—Oil Seal 21—Inlet Port (I1) 22—Inlet Port (V1) 23—Inlet Port (I2) 24—Drain Port (D1) 25—Discharge Port (S1)

Serialized Standard Drive Pump

* Used with 50 needle rollers

CTM7 (28FEB97)

RX,CTM720,5

-20-8

-19-19FEB97

Radial Piston Pumps 280297

PN=50

2000 Series (PR) Hydraulic Pump/Cross-Sectional and Exploded Views

CROSS-SECTION AND EXPLODED VIEW—SINGLE BANK PRESSURE COMPENSATOR—(STANDARD DRIVE PUMP)

R40156

-UN-30NOV88

20 9

1—Compensator Housing 2—O-Ring 3—Packing (2 used) 4—Packing (8 used) 5—Adjusting Screw 6—Spring

7—Spring Guide 8—Pressure Compensator Valve 9—Manual Destroke Screw 10—Plug (Less Manual Destroke Screw)

11—Plug 12—Pin 13—Plug 14—Spring * 15—Crankcase Outlet Valve or Secondary Orifice

* Not used with secondary orifice

CTM7 (28FEB97)

16—Destroke Port Plug 17—Outlet Pressure Plug (T1) 18—Inlet Pressure Plug (T2)

RX,CTM720,6

-20-9

-19-20FEB97

Radial Piston Pumps 280297

PN=51

2000 Series (PR) Hydraulic Pump/Cross-Sectional and Exploded Views

CROSS-SECTION AND EXPLODED VIEW—SINGLE BANK PRESSURE COMPENSATOR—(THROUGH DRIVE PUMP)

R40166

-UN-30NOV88

20 10

1—Compensator Housing 2—O-Ring 3—Packing (2 used) 4—Packing (8 used)

5—Bushing with Stop 6—Adjusting Screw 7—Washer 8—Outer Spring

9—Inner Spring 10—Spring Guide 11—Pressure Compensator Valve

12—Check Valve 13—Spring 14—Manual Destroke Screw

RX,CTM720,7

CTM7 (28FEB97)

-20-10

-19-19FEB97

Radial Piston Pumps 280297

PN=52

2000 Series (PR) Hydraulic Pump/Cross-Sectional and Exploded Views

CROSS-SECTION AND EXPLODED VIEW—DOUBLE BANK PUMP

R40187

-UN-30NOV88

20 11

1—Primary Housing 2—Piston Plug (16 used) 3—Piston Spring (16 or 32 used) 4—Piston (16 used) 5—Secondary Housing 6—Discharge Valve (8 used) 7—Plate 8—Shaft 9—Sealing Ring

10—Bearing Cone (2 used) 11—Sleeve 12—Washer (2 used) 13—Thrust Washer (4 used) 14—Bearing Race (2 used) 15—Needle Roller (50 or 100 used) 16—Spacer (6 used) * 17—Thrust Washer (2 used)

18—Bearing Cup (2 used) 19—Shims (as required) 20—Discharge Valve Seat (16 used) 21—Inlet Valve Plug (16 used) 22—Inlet Valve (16 used) 23—Snap Ring 24—Oil Seal

25—Inlet Port (I1) 26—Inlet Port (V1) 27—Inlet Port (I2) 28—Drain Port (D1) 29—Discharge Port (S1) 30—Inlet Port (V2) 31—Inlet Port (I4) 32—Discharge Port (S2) 33—Inlet Port (I3)

Serialized Pump

* Used with 100 needle rollers

CTM7 (28FEB97)

RX,CTM720,8

-20-11

-19-19FEB97

Radial Piston Pumps 280297

PN=53

2000 Series (PR) Hydraulic Pump/Cross-Sectional and Exploded Views

CROSS-SECTION AND EXPLODED VIEW—DOUBLE BANK PRESSURE COMPENSATOR

R40188

-UN-30NOV88

20 12

1—Compensator Housing 2—O-Ring 3—Packing (2 used) 4—Adjusting Screw 5—Spring

6—Spring Guide 7—Pressure Compensator Valve 8—Manual Destroke Screw 9—Plug (Less Manual Destroke Screw)

10—Plug 11—Pin 12—Plug 13—Spring

14—Crankcase Outlet Valve 15—Destroke Port Plug 16—Outlet Pressure Plug (T1) 17—Inlet Pressure Plug (T2)

Serialized Standard Drive Pump

RX,CTM720,9

CTM7 (28FEB97)

-20-12

-19-19FEB97

Radial Piston Pumps 280297

PN=54

2000 Series (PR) Hydraulic Pump/Piston Assemblies

REMOVE AND INSPECT PISTON ASSEMBLIES

20 13 -UN-22JAN90

IMPORTANT: Pistons must be installed in the original bores if reused. Mark numbers on piston plugs, inlet valve plugs and pump housing for identification.

R39735

1. Remove piston assemblies and place in a parts tray to insure installation into the same bores from which assemblies were removed.

NOTE: Early design (TOP ASSEMBLY IN UPPER PHOTO) for 40 cm3 (2.4 in3) and 50 cm3 (3 in.3) pumps will require ALL new current design piston plugs if piston springs are replaced.

-UN-22JAN90

2. Inspect piston plugs (A) for thread damage.

3. Inspect face and skirt of pistons (E). Replace housing(s) and all pistons or replace entire pump assembly if pistons show metal transfer, galling, or scoring.

IMPORTANT: All springs must be the same color code.

R39944

NOTE: Replacement of early design pistons (TOP ASSEMBLY IN LOWER PHOTO) for 65 cm3 (4 in.3) and 130 cm3 (8 in.3) requires a kit which includes current design (BOTTOM ASSEMBLY IN LOWER PHOTO) pistons, double springs and piston plugs.

A—Piston Plugs B—O-Rings C—Shields D—Piston Springs E—Pistons

4. Inspect springs (D). Replace ALL piston springs as a set.

RX,CTM720,10

CTM7 (28FEB97)

-20-13

-19-17FEB97

Radial Piston Pumps 280297

PN=55

2000 Series (PR) Hydraulic Pump/Check Shaft End Play

INSTALL PISTON ASSEMBLIES 1. Install new O-rings and plastic shields on piston plugs.

-UN-22JAN90

IMPORTANT: To prevent damage to shields, DO NOT use an air-operated wrench to tighten piston plugs; use a torque wrench.

R39702

2. Install piston assemblies. For easier assembly, turn pump shaft so piston being installed is on the low side of cam.

NOTE: Early design (recessed hex) piston plug torque specification is 136 N·m (100 lb-ft).

3. Tighten piston plugs to 185 N·m (135 lb-ft).

RX,CTM720,11

-19-17FEB97

RX,CTM720,12

-19-17FEB97

CHECK SHAFT END PLAY

-UN-22JAN90

1. Remove piston assemblies. (See Remove and Install Piston Assemblies, this group.)

NOTE: Use vice grip with curved jaw for better clamping.

2. Install vice grips as tightly as possible on pump shaft approximately 16 mm (5/8 in.) from housing hub.

R39703

20 14

3. Put a dial indicator base on pump housing. Put indicator contact point on steel ball placed in center of pump shaft.

4. Turn shaft back and forth while pushing down to align the tapered roller bearings inside pump housing.

CTM7 (28FEB97)

-20-14

Radial Piston Pumps 280297

PN=56

2000 Series (PR) Hydraulic Pump/Discharge Valves and Seats 5. Zero the indicator.

6. Pry upward on vice grips using a long (3/4 in. minimum) box-end wrench noting indicator reading. If end play is more than specification, check bearings for wear.

20 15

END PLAY SPECIFICATION Acceptable . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.025—0.100 mm (0.001—0.004 in.)

R39704

-UN-22JAN90

7. Increase number or size of shims in pressure compensator housing on single bank or secondary housing on double bank pump to obtain correct specification.

RX,CTM720,13

-19-17FEB97

RX,CTM720,14

-19-19FEB97

REMOVE, INSPECT, AND INSTALL DISCHARGE VALVES

T85250

-UN-06MAR90

1. Remove pressure compensator housing on single bank pump or secondary housing with pressure compensator housing on double bank pump. (See Remove and Install Pressure Compensator Housing, this group.)

IMPORTANT: Discharge valves must be installed in the original bores.

2. Remove discharge valves and place in a parts tray to insure installation into the same bores from which valves were removed.

CTM7 (28FEB97)

-20-15

Radial Piston Pumps 280297

PN=57

2000 Series (PR) Hydraulic Pump/Discharge Valves and Seats

3. Inspect valve guide (A) for fatigue cracks at tabs and radius of legs.

-UN-26JAN90 R39749

DOUBLE BANK PUMP—Early design (non-serialized pump) discharge valve assembly (Upper parts in BOTTOM photograph) and current design (serialized pump) discharge valve assembly (Bottom parts in BOTTOM photograph.)

Single Bank Valve

4. Inspect stop (D).

5. Inspect springs (C).

-UN-22JAN90

NEW SPRING SPECIFICATION Single Bank-Early Design Free Length (approximate) . . . . . . . . . . . . . . . . . 13.5 mm (0.5 in.)

Test Length . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 mm at 6—7 N (1.4—1.7 lb force) Single Bank-Current Design and Non-Serialized Double Bank

R39750

20 16

NOTE: SINGLE BANK PUMP—Early design discharge valve assembly (Upper parts in UPPER photograph) and current design discharge valve assembly (Bottom parts in UPPER photograph).

Double Bank Valve

Free Length (approximate) . . . . . . . . . . . . . . . . 12.2 mm (0.48 in.)

Test Length . . . . . . . . . . . . . . . . . . . . . . . . 7.6 mm at 11—14 N (0.3 in. at 2.5—3.0 lb force) Serialized Double Bank

A—Valve Guide B—Discharge Valve C—Spring D—Discharge Valve Stop

Free Length (approximate) . . . . . . . . . . . . . . . . . 40.6 mm (1.6 in.)

Test Length . . . . . . . . . . . . . . . . . . . . . . . . 29.7 mm at 39—48 N (1.2 in. at 9—11 lb force)

6. Inspect valve (B) for erosion, pitting or excessive wear. Replace valve if wear is excessive. Discharge valve seat should also be checked for wear. (See Inspect, Remove, and Install Discharge Valve Seats, this group.)

7. Install discharge valves into the original bores.

RX,CTM720,15

CTM7 (28FEB97)

-20-16

-19-21FEB97

Radial Piston Pumps 280297

PN=58

2000 Series (PR) Hydraulic Pump/Discharge Valves and Seats

INSPECT, REMOVE, AND INSTALL DISCHARGE VALVE SEATS

20 17 -UN-06MAR90

1. Wipe discharge seats (B) with your finger accessing seat through the discharge valve bores. This should be done before inspection since oil on valve seat may give impression of seat damage.

T85262

2. Visually inspect discharge valve seats (B) for peening or damage.

IMPORTANT: Press fit is critical for sealing. DO NOT remove discharge valve seats unless replacement is absolutely necessary.

3. Install special screw (A) into seat through piston bore and JDH39B-1 Installer and Removal Tool (A) through discharge valve bore.

4. Install a slide hammer and adapter into the tool and remove seat.

RX,CTM720,16

-19-17FEB97

RX,CTM720,17

-19-17FEB97

T85284

-UN-06MAR90

5. Install new discharge valve seats (B) using JDH39B-1 Installer and Removal Tool (A). Drive seat into housing until flange of tool is against face of housing.

CTM7 (28FEB97)

-20-17

Radial Piston Pumps 280297

PN=59

2000 Series (PR) Hydraulic Pump/Pump Shaft

REMOVE AND INSTALL PUMP SHAFT IMPORTANT: Pistons must be installed in the original bores if reused.

1. Remove piston assemblies. (See Remove and Inspect Piston Assemblies, this group.)

2. Remove pressure compensator housing (and auxiliary gear-driven charge pump if so equipped on single bank pump) and secondary housing on double bank pump.

(See Remove and Install Pressure Compensator Housing, this group.)

RX,CTM720,18

-19-17FEB97

RX,CTM720,19

-19-17FEB97

RX,CTM720,20

-19-17FEB97

IMPORTANT: Discharge valves must be installed in the original bores.

-UN-22JAN90

3. Remove discharge valve assemblies and place in a parts tray.

R39785

4. Remove pump shaft on single bank pump using a hammer to remove bearing cup. Lift shaft from primary housing on double bank pump.

-UN-22JAN90

5. Replace oil seal (and quad ring and backup ring on non-serialized pumps) before installing pump shaft. (See Remove and Install Oil Seal-Pump Disassembled, this group.)

6. Install pump shaft in primary housing using JDG494 Spline Protector to prevent seal damage.

NOTE: Install bearing cup on single bank pump leaving cup partially away from bearing cone. Installation of shims and pressure compensator housing will properly align bearing cup and cone.

CTM7 (28FEB97)

-20-18

R39758

20 18

Radial Piston Pumps 280297

PN=60

2000 Series (PR) Hydraulic Pump/Pump Shaft

DISASSEMBLE AND INSPECT PUMP SHAFT 1. Visually inspect taper bearing cones (A).

20 19 -UN-06FEB90

2. Visually inspect spacers (B) and thrust washers (D).

R36313

3. Inspect race (C) for nicks, scratches, pitting or metal discoloration. Replace race and pistons if external damage exists.

4. Hold pump shaft and slowly turn race (C). If assembly is sticking or noisy, replace all needle rollers between race and pump journal.

A—Bearing Cone B—Spacer C—Race D—Thrust Washer

RX,CTM720,21

-19-17FEB97

RX,CTM720,22

-19-20FEB97

NOTE: Not all pump shafts will have a sealing ring.

-UN-22JAN90

IMPORTANT: Be careful not to scratch or damage shaft surface (A). This could cause seal leakage.

5. Remove sealing ring using a JDG127 O-ring Seal Tool Set.

CTM7 (28FEB97)

R39945

6. Remove bearing cones using a bearing puller.

-20-19

Radial Piston Pumps 280297

PN=61

2000 Series (PR) Hydraulic Pump/Pump Shaft For SINGLE BANK PUMP, perform Steps 7, 8, 9, 10, 11, 12 and 13.

-UN-26JAN90

NOTE: Non-serialized 65 cm3 (4 in.3) pump shaft assembly (TOP photograph) using bronze thrust washers should be updated to design shown in MIDDLE photograph. Kits are available.

R39748

7. Disassemble pump shaft.

8. Inspect bearing (A) shoulder surface. Replace if spacer wear exists.

-UN-30JAN90

NOTE: Some serialized pumps use a double row of needle rollers with a spacer between and on the ends of the rollers as shown in the BOTTOM photograph.)

9. Inspect spacers (B). Replace if worn, scored, or discolored.

R38496

NOTE: Most shafts will not have a lubrication hole in center of journal.

10. Inspect pump shaft journal (C). Replace if pitted, scored, or discolored.

-UN-22JAN90

NOTE: * VESPEL® thrust washers on serialized pump (bottom photograph) may require magnification for inspection.

11. Inspect thrust washers (D).

12. Inspect race (E). Replace if scored or discolored.

13. Inspect needle rollers (F). Replace ALL needle rollers if any are scratched, pitted or discolored.

R39946

20 20

A—Bearing B—Spacer C—Pump Shaft D—Thrust Washers E—Race F—Needle Rollers

* VESPEL® is a trademark of the DuPont Corporation

CTM7 (28FEB97)

RX,CTM720,23

-20-20

-19-17FEB97

Radial Piston Pumps 280297

PN=62

2000 Series (PR) Hydraulic Pump/Pump Shaft For DOUBLE BANK PUMP, perform Steps 7a, 8a, 9a, 10a, 11a, 12a, and 13a.

20 21 -UN-22JAN90

NOTE: Shafts are shown with one race disassembled.

Both races should be disassembled and inspected.

R39739

NOTE: Non-serialized 100 cm3 (6 in.3) pump shaft assembly is shown in TOP photograph and shaft assembly for serialized pump is shown in MIDDLE photograph.

-UN-22JAN90

NOTE: Spacer and thrust washer designs vary. Early designed non-serialized 130 cm3 (8 in.3) shafts using bronze thrust washers (see TOP photograph for single bank pump) should be updated to design shown in MIDDLE photograph.

Kits are available.

7a. Disassemble pump shaft.

R39756

8a. Inspect bearing (A) shoulder surface.

NOTE: Some serialized pumps use a double row of needle rollers with a spacer in between and on the ends of the rollers as shown in the BOTTOM photograph.

-UN-22JAN90

9a. Inspect spacers (B). Replace if worn, scored, or discolored.

10a. Inspect pump shaft journal (C). Replace if pitted, scored, or discolored.

R39946

NOTE: VESPEL® thrust washers on serialized pump (bottom photograph) may require magnification for inspection.

11a. Inspect thrust washers (D). Replace if worn or damaged.

12a. Inspect race (E). Replace if scored or discolored.

13a. Inspect needle rollers (F). Replace ALL needle rollers if any are scratched, pitted or discolored.

A—Bearing B—Spacers C—Pump Shaft D—Thrust Washers E—Race F—Needle Rollers

RX,CTM720,24

CTM7 (28FEB97)

-20-21

-19-17FEB97

Radial Piston Pumps 280297

PN=63

2000 Series (PR) Hydraulic Pump/Pump Shaft

ASSEMBLE PUMP SHAFT— SINGLE BANK PUMP

R39600

-UN-22JAN90

NOTE: 36 needle rollers are used on NON-SERIALIZED 40 cm3 (2.4 in.3) and 50 cm3 (3 in.3) pumps. 25 are used on all other single bank pumps with single row needle rollers. 50 needle rollers are used on single bank pumps with double row needle rollers.

IMPORTANT: DO NOT use grease to hold needle rollers. Doing so can restrain roller movement and cause pump failure.

Use only clean hydraulic oil.

-UN-30JAN90

Three small spacers must be installed between and on both ends of needle rollers for pumps using double row needle rollers.

1. Assemble shaft needle rollers using a rubber band to aid installation.

R38497

20 22

2. Install spacers (B) on shaft (A) making sure spacers are correctly aligned.

IMPORTANT: Taper roller bearings must be pressed onto pump shaft even if shaft has not been disassembled. This assures correct pump shaft end play.

3. Install bearing cones (C) using a bearing press, making sure cone is pressed against shaft journal.

RX,CTM720,25

CTM7 (28FEB97)

-20-22

-19-17FEB97

Radial Piston Pumps 280297

PN=64

2000 Series (PR) Hydraulic Pump/Pump Shaft NOTE: Not all shafts will have a sealing ring. Through drive shafts use sealing rings on both ends of shaft.

20 23 -UN-02FEB90

Use optional JDG493 Shaft Seal Sizer Tool (A) to aid sealing ring installation.

R37912

4. Install JDG494 Spline Protector Tool (C) on pump shaft.

5. Carefully slide new sealing ring (B) over spline protector and down into groove on pump shaft making sure sealing ring does not twist. Use optional JDG493 Sizing Tool (A) to aid installation.

-UN-22JAN90

NOTE: Optional JDG493 Sizing Tool may be used in place of hose clamp.

R39604

6. Clamp sealing ring in groove using a hose clamp. Put shim stock between clamp and sealing ring to prevent sealing ring damage. Leave hose clamp in place approximately five minutes to allow sealing ring to set.

RX,CTM720,26

-19-17FEB97

RX,CTM720,27

-19-17FEB97

ASSEMBLE PUMP SHAFT— DOUBLE BANK PUMP

-UN-22JAN90

NOTE: 26 needle rollers per race assembly are used on 100 cm3 (6 in.3) NON-SERIALIZED pumps. 25 or 50 needle rollers per race are used on all other double bank pumps.

R39600

IMPORTANT: DO NOT use grease to hold needle rollers. Doing so can restrain roller movement and cause pump failure.

Use only clean hydraulic oil.

Three small spacers must be installed between and on both ends of needle rollers for serialized pumps using double row needle rollers.

1. Assemble shaft needle rollers using a rubber band to aid installation. (See procedure for single bank pump shaft assembly.)

CTM7 (28FEB97)

-20-23

Radial Piston Pumps 280297

PN=65

2000 Series (PR) Hydraulic Pump/Pump Shaft For 100 cm3 (6 in.3) NON-SERIALIZED double bank pump, perform Steps 2a and 3a.

-UN-22JAN90

IMPORTANT: Bronze thrust washer MUST be installed with ID radius of thrust washer in alignment with radius on inside of shaft journal.

R39789

2a. Assemble shaft installing thick bronze thrust washer (A) on shaft (E) making sure ID radius of thrust washer is toward center of shaft.

NOTE: Center collar sleeve must be installed on shaft prior to pressing bearing cone in place.

A—Bronze Thrust Washers B—Spacers C—Needle Rollers D—Race E—Shaft F—Bearing Cone

3a. Install bearing cones (F) using a bearing press, making sure cone is pressed against shaft journal.

RX,CTM720,28

-19-17FEB97

RX,CTM720,29

-19-19FEB97

For 130 cm3 (8 in.3) NON-SERIALIZED and ALL SERIALIZED double bank pumps, perform Steps 2b and 3b.

-UN-22JAN90

IMPORTANT: Thick spacer MUST be installed with ID radius of spacer in alignment with radius on inside of shaft journal.

2b. Assemble shaft installing thick spacer (A) on shaft (F) making sure ID radius of spacer is toward center of shaft.

R39757

20 24

NOTE: Center collar sleeve must be installed on shaft prior to pressing bearing cone in position.

A—Thick Spacer B—Needle Rollers C—Thrust Washer D—Race E—Spacer F—Shaft G—Bearing Cone

3b. Install bearing cones (G) using a bearing press making sure cone is pressed against shaft journal.

CTM7 (28FEB97)

-20-24

Radial Piston Pumps 280297

PN=66

2000 Series (PR) Hydraulic Pump/Pump Housing NOTE: Not all shafts will have a sealing ring. Through drive shafts use sealing rings on both ends of shaft.

20 25 -UN-02FEB90

4. Install JDG494 Spline Protector Tool (C) on pump shaft.

R37912

5. Carefully slide new sealing ring (B) over spline protector and down into groove on pump shaft making sure sealing ring does not twist. Use JDG493 Pump Shaft Seal Sizer (A) to aid installation.

NOTE: JDG493 Pump Shaft Seal Sizer may be used instead of hose clamp.

R39604

-UN-22JAN90

6. Clamp sealing ring in groove using a hose clamp. Put shim stock between clamp and sealing ring to prevent sealing ring damage. Leave hose clamp in place approximately five minutes to allow sealing ring to set.

RX,CTM720,30

-19-25FEB97

RX,CTM720,31

-19-17FEB97

INSPECT PUMP HOUSING

-UN-02MAR90

1. Inspect piston bores (B) in pump housing (A). Replace housing and pistons if scoring, galling or metal transfer exists.

CTM7 (28FEB97)

-20-25

RW3528

2. After visual inspection, install each piston (C) into original bore until piston extends approximately 13 mm (0.5 in.) into crankcase. Pistons must slide smoothly and have no side play. If any side play is found, replace housing and pistons.

Radial Piston Pumps 280297

PN=67

2000 Series (PR) Hydraulic Pump/Bearing Cups

INSPECT BEARING CUPS

-UN-22JAN90

IMPORTANT: Bearing cups must be used with the same cones.

Pump housing, bearing cones and cups must be replaced if bearing cups show signs of spinning.

NOTE: Save shims from secondary housing on double bank pump for reassembly.

R39503

20 26

1. Remove bearing cups using a slide hammer and a bearing cup puller.

2. Inspect bearing cups for damage. Put bearing cup on cone and turn slowly. If bearing makes a clicking noise or is sticking, clean and dip cone in clean hydraulic oil.

Turn again and replace if bearing continues to click or stick.

RX,CTM720,32

CTM7 (28FEB97)

-20-26

-19-17FEB97

Radial Piston Pumps 280297

PN=68

2000 Series (PR) Hydraulic Pump/Shaft Seals

REMOVE AND INSTALL SHAFT SEAL— PUMP ASSEMBLED

20 27 -UN-22JAN90

NOTE: JDH32 Hydraulic Pump Seal Replacement Set can only be on older seal designs.

1. Remove shaft oil seal retaining snap ring in housing.

R39947

For use with JDH32 Puller (older seal design), perform Steps 2a, 3a, and 4a.

2a. Put JDH35A Seal Puller form JDH32 Hydraulic Pump Seal Replacement Set on pump shaft.

3a. Screw body (A) of puller into gland of oil seal as far as possible.

4a. Remove seal by tightening screw in puller.

For current design seals, perform Steps 2b, 3b, and 4b.

2b. Disconnect hydraulic pump lines to eliminate possible back feed pressure.

3b. Connect a low-pressure line to the seal drain line port in the pump body.

4b. Apply approximately 1380—3450 kPa (13.8—34.5 bar) (200—500 psi) using a hand pump to remove the seal.

RX,CTM720,33

CTM7 (28FEB97)

-20-27

-19-20FEB97

Radial Piston Pumps 280297

PN=69

2000 Series (PR) Hydraulic Pump/Shaft Seals

-UN-22JAN90

5. Put JDG494 Spline Protector on shaft to prevent seal damage.

R39948

6. Apply petroleum jelly to lips of new oil seal siding seal with lip (spring side) toward inside of pump down over spline protector.

7. Remove spline protector and use JDH31A Seal Driver (A) from JDH32 Hydraulic Pump Seal Replacement Set to install oil seal. Oil seal should be installed just far enough to install retaining snap ring.

8. Install retaining snap ring.

RX,CTM720,34

-19-19FEB97

RX,CTM720,35

-19-17FEB97

REMOVE AND INSTALL OIL SEAL— PUMP DISASSEMBLED

-UN-22JAN90

NOTE: Through drive pump shaft uses oil seals on both ends of pump shaft.

1. Remove oil seal retaining snap ring.

2. Remove oil seal using a puller and slide hammer.

R39751

20 28

IMPORTANT: DO NOT push oil seal beyond inner edge of snap ring groove. Doing so can close drain passage and cause an oil seal failure.

CTM7 (28FEB97)

-20-28

Radial Piston Pumps 280297

PN=70

2000 Series (PR) Hydraulic Pump/Inlet Valves For NON-SERIALIZED single bank pump, perform Steps 2a and 2b.

20 29 -UN-22JAN90

2a. Remove and discard backup ring (A) and quad ring (B).

R39752

2b. Install new backup ring (A) and quad ring (B) into groove inside pump housing. Quad ring should be toward inside of housing.

RX,CTM720,36

-19-17FEB97

RX,CTM720,37

-19-17FEB97

RX,CTM720,38

-19-19FEB97

-UN-09MAR90

IMPORTANT: DO NOT push oil seal beyond inner edge of snap ring groove. Doing so can close drain passage and cause an oil seal failure.

NOTE: Use a 1-15/16 in. disk from a Bushing, Bearing and Seal Driver Set to aid installation.

T85279

3. Install oil seal (A) with lip (spring side) toward inside of pump housing making sure drain passage is not blocked.

4. Apply petroleum jelly to lips of oil seal for lubrication when shaft is installed.

5. Install retaining snap ring.

INSPECT, REMOVE, AND INSTALL INLET VALVES

-UN-02MAR90

1. Remove inlet valve plugs.

RW3529

2. Check inlet valves for smooth valve movement and valve lift. If valves are not broken and move smoothly, do not remove.

CTM7 (28FEB97)

-20-29

Radial Piston Pumps 280297

PN=71

2000 Series (PR) Hydraulic Pump/Pressure Compensator Housing

-UN-02MAR90

NOTE: For double bank pump, reinstalling secondary housing onto primary may aid in removing inlet valve plugs.

RW3530

3. Remove inlet valves.

4. Install new inlet valve assemblies using valve plugs to push inlet valves into the original bores.

5. Tighten inlet valve plugs (A) to 136 N·m (100 lb-ft).

6. Loosen plugs and retighten to 136 N·m (100 lb-ft) to seat inlet valves.

RX,CTM720,39

-19-17FEB97

RX,CTM720,40

-19-17FEB97

REMOVE AND INSTALL PRESSURE COMPENSATOR HOUSING

-UN-22JAN90

IMPORTANT: Disassemble pressure compensator only if there is evidence of malfunction.

CAUTION: For double bank pump—remove compensator housing only when pump is mounted on a bench fixture. Cap screws for compensator housing also hold secondary housing to primary housing.

R39763

20 30

IMPORTANT: Removed inlet valves must be replaced with new valves since press fit is critical for sealing.

NOTE: Compensator housing does not have to be removed from pump for servicing.

1. Thoroughly clean outside surface before removing housing.

2. Remove electric destroke solenoid (A), if so equipped, to prevent damage to solenoid during compensator repair.

3. Loosen plugs then remove compensator housing.

CTM7 (28FEB97)

-20-30

Radial Piston Pumps 280297

PN=72

2000 Series (PR) Hydraulic Pump/Pressure Compensator Housing For pump with Auxiliary Gear-Driven Charge Pump, perform Step 3a.

20 31

R37618

-UN-01FEB90

3a. Install new charge pump drive seal in compensator housing.

RX,CTM720,41

-19-17FEB97

RX,CTM720,42

-19-17FEB97

RX,CTM720,43

-19-19FEB97

NOTE: Standard drive single bank compensator housing is shown. Double bank compensator housing does not use packings (B) or shims (D).

T85462

-UN-02MAR90

IMPORTANT: DO NOT install O-rings or packings if end play was out of specification, or bearing cones and cups have been replaced. Install O-rings and packings after correct end play is established.

NOTE: Apply a small amount of petroleum jelly to O-ring, packings and shims to hold them in place during assembly.

A—O-Ring B—Packings C—Packings D—Shims

4. Install shims to check end play specification.

5. Install new O-rings and packings (A—C).

6. Install new O-rings (C—D) and backup ring (E) on destroke plug (A) or electric destroke solenoid valve (B).

-UN-22JAN90

IMPORTANT: Torque specification for solenoid valve (34 N·m (25 lb-ft) is different than destroke plug (61 N·m (45 lb-ft). Over tightening electric destroke solenoid may cause pump to malfunction.

R39770

7. Install destroke plug (A) or electric destroke solenoid valve (B) into housing.

A—Destroke Plug B—Electric Destroke Solenoid C—O-Rings D—O-Rings E—Backup Rings

CTM7 (28FEB97)

-20-31

Radial Piston Pumps 280297

PN=73

2000 Series (PR) Hydraulic Pump/Pressure Compensator Housing

CAUTION: DO NOT INSTALL a serialized pump compensator housing on an early design non-serialized pump or an early design compensator housing (non-serialized) on a serialized pump. The mounting holes are common, but the HIGH-PRESSURE PASSAGES WILL NOT ALIGN. Failure to align the high-pressure passages will keep the pump in full stroke. This could result in hydraulic system damage and possibly a high-pressure leak which could create a risk of personal injury.

-UN-28FEB90

NOTE: Pressure passage location will differ between single bank and double bank pumps and also differ between non-serialized and serialized pumps.

8. Install compensator housing (C) to pump housing (D) making sure system-pressure passages (A) and charge-pressure passages (B) are aligned.

9. Tighten cap screws to 70 N·m (50 lb-ft). Continue tightening cap screws alternately to 115 N·m (85 lb-ft).

T86280

20 32

NOTE: Some double bank pumps may have a special dowel pin between the compensator housing and secondary pump housing to insure correct alignment.

A—System Pressure Passages B—Charge Pressure Passages C—Pressure Compensator Housing D—Pump Housing

RX,CTM720,44

CTM7 (28FEB97)

-20-32

-19-19FEB97

Radial Piston Pumps 280297

PN=74

2000 Series (PR) Hydraulic Pump/Pressure Compensator Valve

DISASSEMBLE, INSPECT, AND ASSEMBLE PRESSURE COMPENSATOR VALVE— STD. AND AUX. GEAR DRIVE PUMPS

20 33

NOTE: Two manual destroke screws and two spring and spring guide assemblies are shown.

IMPORTANT: Remove adjusting screw and bushing assembly (A) prior to removing manual destroke screw (or plug if manual destroke is not used). Pressure compensator valve sleeve packings will be damaged if adjusting screw and bushing assembly are not removed first.

1. Remove parts (A—G).

-UN-22JAN90

NOTE: Spring (C) uses long spring guide (E) and spring (D) uses short spring guide (F).

2. Inspect spring (C) or (D).

Spring (C) Free Length (approximate) . . . . . . . . . . . . . . . . . . 92 mm (3.6 in.)

Test Length . . . . . . . . . . . . . . . . . . . . . . . 84 mm at 556—690 N (3.3 in. at 125—155 lb force) Spring (D) Free Length (approximate) . . . . . . . . . . . . . . . . . . 90 mm (3.5 in.)

Test Length . . . . . . . . . . . . . . . . . . . . . . . 75 mm at 801—979 N (3.0 in. at 180—220 lb force)

3. Inspect spring guide (E) or (F).

R39764

NEW SPRING SPECIFICATION

A—Adjusting Screw and Bushing B—Special Washers C—Spring D—Spring E—Spring Guide F—Spring Guide G—Pressure Compensator Valve H—Manual Destroke Screws

RX,CTM720,45

-19-17FEB97

RX,CTM720,46

-19-17FEB97

-UN-01FEB90

IMPORTANT: DO NOT use a punch to remove pressure compensator valve sleeve (and crankcase outlet valve sleeve or fixed orifice sleeve in non-serialized pumps). Sleeve(s) could be damaged and cause sticking.

CTM7 (28FEB97)

-20-33

R37715

4. Carefully remove pressure compensator valve sleeve using a wood or brass dowel. Remove from manual destroke opening toward adjusting screw opening.

Radial Piston Pumps 280297

PN=75

2000 Series (PR) Hydraulic Pump/Pressure Compensator Valve

-UN-01FEB90

6. Replace O-ring and backup ring on sleeve.

C—Sleeve Bore D—Valve

R37639

A—Valve Face B—Valve Seat

RX,CTM720,47

-19-17FEB97

RX,CTM720,48

-19-19FEB97

RX,CTM720,49

-19-17FEB97

IMPORTANT: All compensator valve parts must be thoroughly cleaned. All passage holes in parts must be open and clean.

R39771

-UN-22JAN90

7. Install new O-ring (A) (and backup ring (B) in serialized pump) through manual destroke port (C) in compensator housing. Use a JDH6 O-ring Seal Hook to aid installation.

-UN-02MAR90

IMPORTANT: DO NOT use a punch to install pressure compensator sleeve. Damage could occur to the sleeve and cause sticking.

8. Carefully install pressure compensator valve sleeve through adjusting screw port making sure sleeve seating surfaces are not damaged. Push sleeve against manual destroke using a wood or brass dowel.

T85474

20 34

5. Inspect pressure compensator valve assembly.

Valve (D) must move freely in bore (C). Valve face (A) and seat (B) must be free of pits or nicks. Replace valve and sleeve if drag or damage exists.

CTM7 (28FEB97)

-20-34

Radial Piston Pumps 280297

PN=76

2000 Series (PR) Hydraulic Pump/Pressure Compensator Valve 9. Install manual destroke or plug with new O-rings into compensator housing.

20 35

10. Install pressure compensator valve (H) into sleeve in housing.

11. Install long spring guide (F) with spring (D) or short spring guide (G) with spring (E).

NOTE: Copper washer (B) is used with spring (D) and spring guide (F), and thick washer (C) is used with spring (E) and spring guide (G). Some applications may use both washer (B) and (C).

12. Install adjusting screw and bushing assembly (A) with copper washer (B) or thick washer (C).

R39775

-UN-22JAN90

A—Adjusting Screw and Bushing B—Copper Washer C—Thick Washer D—Spring E—Spring F—Spring Guide G—Spring Guide H—Pressure Compensator Valve

RX,CTM720,50

-19-17FEB97

RX,CTM720,51

-19-17FEB97

DISASSEMBLE, INSPECT, AND ASSEMBLE PRESSURE COMPENSATOR VALVE— THROUGH DRIVE PUMP -UN-22JAN90

1. Slowly loosen pressure adjusting screw (A) to relieve any crankcase pressure.

2. Remove adjusting screw and sleeve assembly (B).

R39949

NOTE: Not all pressure adjusting assemblies will use the smaller inner spring (D).

3. Inspect springs (C) and (D) and spring guide (E).

NEW SPRING SPECIFICATION Spring (C) Free Length (approximate) . . . . . . . . . . . . . . . . . . 97 mm (3.8 in.)

Test Length . . . . . . . . . . . . . . . . . . . . . . 78 mm at 1340—1640 N (3.1 in. at 300—370 lb force) Spring (D) Free Length (approximate) . . . . . . . . . . . . . . . . . . 92 mm (3.6 in.)

Test Length . . . . . . . . . . . . . . . . . . . . . . . 79 mm at 495—605 N (3.1 in. at 110—135 lb force)

CTM7 (28FEB97)

-20-35

Radial Piston Pumps 280297

PN=77

2000 Series (PR) Hydraulic Pump/Pressure Compensator Valve 4. Remove and inspect pressure compensator valve plug (A), dampening spring (B) and valve (C).

20 36

NEW SPRING SPECIFICATION

R39950

-UN-22JAN90

Free Length (approximate) . . . . . . . . . . . . . . . . . . 20.6 mm (0.8 in.)

Test Length . . . . . . . . . . . . . . . . . . . . . . . 13.7 mm at 200—247 N (0.5 in. at 45—55 lb force)

RX,CTM720,52

-19-19FEB97

RX,CTM720,53

-19-17FEB97

RX,CTM720,54

-19-17FEB97

-UN-23JAN90

5. Install small end of DFRW52 Pressure Compensator Valve Installation and Removal Tool (A) in center of valve assembly inside pressure compensator housing.

(See Dealer Fabricated Tools, Group 99.)

R40164

6. Carefully push on tool to remove pressure compensator valve assembly (B).

7. Inspect pressure compensator valve assembly.

Valve (A) must slide smoothly in sleeve (B). Replace assembly if valve sticks in sleeve.

R39616

-UN-22JAN90

8. Replace backup ring (C) and O-ring (D).

CTM7 (28FEB97)

-20-36

Radial Piston Pumps 280297

PN=78

2000 Series (PR) Hydraulic Pump/Crankcase Outlet Valve IMPORTANT: Make sure valve and sleeve are assembled correctly. Incorrect assembling will cause pump malfunction.

-UN-23JAN90

20 37

9. Carefully install valve assembly into housing using DFRW52 Pressure Compensator Valve Installation and Removal Tool. Push until valve bottoms out in housing.

11. Install spring guide (E), spring(s) (C) and (D), sleeve assembly (B) and adjusting screw (A). Adjusting screw should be set to a minimum depth to prevent excessive deadhead pressure at start up.

R40165

10. Install pressure compensator valve plug assembly.

A—Adjusting Screw B—Sleeve Assembly C—Outer Spring

D—Inner Spring E—Spring Guide

RX,CTM720,55

-19-17FEB97

RX,CTM720,56

-19-17FEB97

REMOVE, INSPECT, AND INSTALL CRANKCASE OUTLET VALVE— NON-SERIALIZED PUMPS 1. Remove crankcase outlet valve plug (A) with shims (B), spring (C) and spring retainer (D).

2. Remove filter (F) from housing and clean or replace.

3. Inspect spring (C).

NEW SPRING SPECIFICATION Free Length (approximate) . . . . . . . . . . . . . . . . . 73.5 mm (2.9 in.)

Test Length . . . . . . . . . . . . . . . . . . . . . . . 56 mm at 200—245 N (2.2 in. at 45—55 lb force)

F—Filter G—Crankcase Outlet Valve H—Plug

R39776

A—Plug B—Shims C—Spring D—Spring Retainer E—Packings

-UN-22JAN90

4. Remove plug (H) and crankcase outlet valve (G) from housing.

CTM7 (28FEB97)

-20-37

Radial Piston Pumps 280297

PN=79

2000 Series (PR) Hydraulic Pump/Crankcase Outlet Valve

-UN-01FEB90 R37715

5. Carefully remove crankcase outlet valve sleeve (or fixed orifice sleeve) through other bore in pressure compensator housing. Remove in the same direction as pressure compensator valve sleeve.

RX,CTM720,57

-19-17FEB97

RX,CTM720,58

-19-17FEB97

RX,CTM720,59

-19-17FEB97

6. Inspect crankcase outlet valve assembly. Valve (A) must move smoothly in bore of sleeve (B). Replace valve and sleeve if drag or damage exits.

R39769

-UN-22JAN90

7. Install new O-ring on crankcase outlet valve sleeve.

-UN-22JAN90

8. Install new O-ring (A) in internal housing groove through crankcase outlet valve port (B). Use an JDH6 O-ring Seal Hook to aid installation.

R39772

20 38

IMPORTANT: DO NOT use a punch to remove pressure compensator valve sleeve (and crankcase outlet valve sleeve or fixed orifice sleeve in non-serialized pumps). Sleeve(s) could be damaged and cause sticking.

CTM7 (28FEB97)

-20-38

Radial Piston Pumps 280297

PN=80

2000 Series (PR) Hydraulic Pump/Crankcase Outlet Valve 9. Install O-ring on crankcase outlet valve sleeve (or fixed orifice sleeve).

20 39 -UN-22JAN90

IMPORTANT: Do not use a punch to install crankcase outlet valve sleeve (or orifice sleeve). Damage could occur to sleeve.

R39774

10. Carefully install crankcase outlet valve sleeve (or fixed orifice sleeve) through port next to adjusting screw port making sure sleeve seating surfaces are not damaged. Push sleeve against internal housing stop using a wood or brass dowel.

RX,CTM720,60

-19-17FEB97

RX,CTM720,61

-19-17FEB97

11. Put new O-rings on crankcase outlet valve plug (A) and plug with pin (H).

12. Put new packings (E) on filter (F) and install filter assembly into pressure compensator housing.

13. Install shims (B), spring (C) and spring retainer (D) on crankcase outlet valve plug with pin (A). Install into housing.

NOTE: DO NOT install plug with pin (H). Crankcase outlet valve must be adjusted.

14. Carefully install crankcase outlet valve (G) into sleeve in housing.

R39776

-UN-22JAN90

A—Crankcase Outlet Valve Plug B—Shims C—Spring D—Spring Retainer E—Packings F—Filter G—Crankcase Outlet Valve H—Plug with Pin

CTM7 (28FEB97)

-20-39

Radial Piston Pumps 280297

PN=81

2000 Series (PR) Hydraulic Pump/Crankcase Outlet Valve

ADJUST CRANKCASE OUTLET VALVE— NON-SERIALIZED PUMPS IMPORTANT: Early version tools JDH19 and JDG19A use a washer, JDH19B and JDG19C do not. Using a washer on “B” and “C” version tools will result in a considerable decrease in pump performance.

1. Install JDH19C Adjusting Tool (A) to adjust crankcase outlet valve.

2. Add or deduct shims (C) to crankcase outlet valve plug (D) until bottom of notch in center pin (B) of adjusting tool is even with top of nut.

-UN-22JAN90

3. Remove tool and push on crankcase outlet valve in housing to be sure valve moves freely in sleeve.

4. Install the plug with pin.

R39777

20 40

RX,CTM720,62

CTM7 (28FEB97)

-20-40

-19-17FEB97

Radial Piston Pumps 280297

PN=82

2000 Series (PR) Hydraulic Pump/Crankcase Outlet Valve

REMOVE, INSPECT, AND INSTALL CRANKCASE OUTLET VALVE— SERIALIZED PUMPS

20 41

1. Remove crankcase outlet valve plug (A), spring (B) and crankcase outlet valve (C) from housing.

NOTE: Spring, in some applications, may have been removed for circuits using external pump control.

2. Inspect spring (B).

NEW SPRING SPECIFICATION Free Length (approximate) . . . . . . . . . . . . . . . . . . . 87 mm (3.4 in.)

Test Length . . . . . . . . . . . . . . . . . . . . . . . . . 74.5 mm at 63—77 N (3.0 in. at 14—17 lb force)

-UN-22JAN90

3. Remove resonator plug (E) and pin (D) from housing.

IMPORTANT: Pin (D) and crankcase outlet valve (C) must slide smoothly in housing bores.

R39767

4. Inspect crankcase outlet valve (C) and pin (D).

5. Install new O-rings on crankcase outlet valve plug (A) and resonator plug (E).

6. Carefully install crankcase valve assembly into housing.

A—Crankcase Outlet B—Spring C—Crankcase Outlet Valve D—Pin E—Resonator Plug

RX,CTM720,63

CTM7 (28FEB97)

-20-41

-19-17FEB97

Radial Piston Pumps 280297

PN=83

2000 Series (PR) Hydraulic Pump/Fixed Orifice

REMOVE, INSPECT, AND INSTALL FIXED ORIFICE—NON-SERIALIZED PUMPS 1. Remove filter (C) with packings (B). Clean or replace filter.

2. Remove plug (D) to remove orifice sleeve inside housing. (See procedure for removing and installing crankcase outlet valve sleeve in this group.)

3. Install new packings and O-rings on sleeve, plugs and filter and reassemble.

R39791

-UN-22JAN90

A—Plug B—Packings C—Filter D—Plug

RX,CTM720,64

-19-17FEB97

RX,CTM720,65

-19-17FEB97

REMOVE, INSPECT, AND ASSEMBLE FIXED ORIFICE—SERIALIZED PUMPS 1. Remove plugs (A) and (C).

2. Remove and inspect fixed orifice sleeve (B).

-UN-22JAN90

3. Install new O-rings on plugs and reassemble fixed orifice.

R39790

20 42

CTM7 (28FEB97)

-20-42

Radial Piston Pumps 280297

PN=84

Group 25

3000 Series (HPR) Hydraulic Pump ESSENTIAL OR RECOMMENDED TOOLS NOTE: Order tools from the U.S. SERVICE-GARD™ or European Microfiche Tool Catalogs.

RECOMMENDED TOOLS, as noted, are suggested to perform the job correctly. Some tools may be available from local suppliers or may be fabricated.

25 1

ESSENTIAL TOOLS listed are required to perform the job correctly and are obtainable only from SERVICE-GARD or European Tool Catalogs.

RX,TOOLS RW25125

-19-21APR94

-UN-14APR94

Bench-Mounted Holding Fixture . . . . . . . . . D01006AA* Hold components during disassembly and assembly * RECOMMENDED TOOL RW25634

RX,D01006AA

-19-25NOV96

RX,DFRW52A

-19-17FEB97

RX,JDG127

-19-17FEB97

RX,JDG493

-19-14FEB97

-UN-14FEB97

Pressure Compensator Valve Tool . . . . . . . . DFRW52* Remove and install pressure compensator valve and sleeve in non-unitized inlet housing

* RECOMMENDED TOOL—See Group 99 for tool fabrication RW25636

O-Ring Seal Tool Set . . . . . . . . . . . . . . . .

-UN-19FEB97

JDG127*

Protect machined surfaces when replacing O-rings * RECOMMENDED TOOL RW25635

Pump Shaft Seal Sizer . . . . . . . . . . . . . . .

-UN-14FEB97

JDG493*

Install sealing ring in pump shaft * RECOMMENDED TOOL R40151

-UN-23AUG88

Spline Protector . . . . . . . . . . . . . . . . . . . . . JDG494 Install pump shaft

JDG494

CTM7 (28FEB97)

-25-1

-19-18DEC90

Radial Piston Pumps 280297

PN=85

3000 Series (HPR) Hydraulic Pump/Service Equipment and Tools R40153

-UN-23AUG88

Hydraulic Pump Seat Installation and Removal Tool . . . . . . . . . . . . . . . . . . . JDG539

25 2

Install and remove discharge valve seats

RW25637

JDG539

-19-19DEC90

RX,JDH6

-19-17FEB97

-UN-19FEB97

O-Ring Seal Hook . . . . . . . . . . . . . . . . . . . . . JDH6* Remove and install O-ring seals * RECOMMENDED TOOL

SERVICE EQUIPMENT AND TOOLS NOTE: Order tools from the U.S. SERVICEGARD™ Catalog or from the European Microfiche Tool Catalog (MTC). Some tools may be available from a local supplier.

Name

Use

JT05714 Hydraulic Pump Parts Tray

Organize, identify, and protect pump parts during repair

RX,CTM715,1

CTM7 (28FEB97)

-25-2

-19-19FEB97

Radial Piston Pumps 280297

PN=86

3000 Series (HPR) Hydraulic Pump/Specifications

HYDRAULIC PUMP—3000 SERIES SPECIFICATIONS

25 3

Item

Measurement

Specification

Discharge Valve Plug

Torque

140 N·m (100 lb-ft)

Piston Plug

Torque

200 N·m (150 lb-ft)

Manifold-to-Pump (Double Bank with “B” Drive)

Torque

90 N·m (65 lb-ft)

Pump Shaft

End Play

0.025—0.100 mm (0.001—0.004 in.)

Piston

OD

25.363—25.373 mm (0.9985—0.9989 in.)

Piston Bore

ID

25.395—25.405 mm (0.9998—1.0001 in.)

Inlet Valve

Lift

2.7—3.7 mm (0.11—0.15 in.)

Piston Spring

Free Length (approximate) Test Length

77 mm (3.0 in.)

54.4 mm at 240—295 N (2.1 in. at 54—66 lb force)

Discharge Valve Spring

Free Length (approximate) Test Length

12.7 mm (0.5 in.)

9.3 mm at 17—24 N (0.4 in. at 4—5 lb force) RX,CTM725,1

CTM7 (28FEB97)

-25-3

-19-20FEB97

Radial Piston Pumps 280297

PN=87

3000 Series (HPR) Hydraulic Pump/Specifications

CONTROL VALVE TORQUE SPECIFICATIONS

25 4

Item

Measurement

Specification

Inlet Housing-to-Pump

Torque

200 N·m (150 lb-ft)

Valve Housing-to-Inlet Housing (Unitized Design)

Torque

15 N·m (11 lb-ft)

Test Port Plug

Torque

34 N·m (25 lb-ft)

Destroke Plug or Manual Destroke

Torque

61 N·m (45 lb-ft)

Electric Destroke Solenoid Valve

Torque

34 N·m (25 lb-ft)

RX,CTM725,2

CTM7 (28FEB97)

-25-4

-19-17FEB97

Radial Piston Pumps 280297

PN=88

3000 Series (HPR) Hydraulic Pump/Specifications

CONTROL VALVE—NON-UNITIZED DESIGN SPECIFICATIONS

25 5

Item

Measurement

Specification

Compensator Valve Dampening Spring

Free Length (approximate) Test Length

20.6 mm (0.8 in.)

13.7 mm at 200—247 N (0.5 in. at 45—55 lb force)

Shuttle Valve Spring

Free Length (approximate) Test Length

45 mm (1.8 in.)

26.5 mm at 175—218 N (1.0 in. at 40—49 lb force)

Green

Free Length (approximate) Test Length

93.6 mm (3.7 in.)

80 mm at 706—864 N (3.2 in. at 159—194 lb force)

Red

Free Length (approximate) Test Length

95.5 mm (3.8 in.)

80 mm at 1131—1383 N (3.2 in. at 254—311 lb force)

Blue

Free Length (approximate) Test Length

91.3 mm (3.6 in.)

79.4 mm at 1152—1408 N (3.1 in. at 259—317 lb force)

No Color

Free Length (approximate) Test Length

97.5 mm (3.8 in.)

80 mm at 1620—1980 N (3.2 in. at 364—445 lb force)

No Color

Free Length (approximate) Test Length

97 mm (3.8 in.)

78 mm at 1340—1640 N (3.1 in. at 300—370 lb force)

Green

Free Length (approximate) Test Length

96 mm (3.7 in.)

82 mm at 780 N (3.2 in. at 175 lb force)

Free Length (approximate) Test Length

92 mm (3.6 in.)

79 mm at 495 —605 N (3.1 in. at 110—135 lb force)

Without Spring Sleeve Compensator Valve Spring:

With Spring Sleeve *Compensator Valve Spring:

Outer Spring

Inner Spring (if used)

* Spring and sleeve assemblies with one row of holes in the end of sleeve are not serviceable or interchangeable with design having two rows of holes in sleeve.

CTM7 (28FEB97)

-25-5

RX,CTM725,3

-19-20FEB97

Radial Piston Pumps 280297

PN=89

3000 Series (HPR) Hydraulic Pump/Specifications

CONTROL VALVE—UNITIZED DESIGN SPECIFICATIONS

25 6

Item

Measurement

Specification

Red

Free Length (approximate) Test Length

71 mm (2.8 in.)

60 mm at 580—700 N (2.4 in. at 130—158 lb force)

Blue

Free Length (approximate) Test Length

71 mm (2.8 in.)

60 mm at 930—1130 N (2.4 in. at 210—254 lb force)

Free Length (approximate) Test Length

68 mm (2.7 in.)

58 mm at 270—330 N (2.3 in. at 60—74 lb force)

Crankcase Relief Valve Spring

Free Length (approximate) Test Length

51 mm (2.0 in.)

37 mm at 200—245 N (1.5 in. at 45—55 lb force)

Shuttle Valve Spring

Free Length (approximate) Test Length

44 mm (1.7 in.)

22 mm at 18—22 N (0.9 in. at 4—5 lb force)

Red

Free Length (approximate) Test Length

71 mm (2.8 in.)

60 mm at 580—700 N (2.4 in. at 130—158 lb force)

Blue

Free Length (approximate) Test Length

71 mm (1.8 in.)

60 mm at 930—1130 N (2.4 in. at 210—254 lb force)

Free Length (approximate) Test Length

68 mm (2.7 in.)

58 mm at 270—330 N (2.3 in. at 60—74 lb force)

PRESSURE COMPENSATOR VALVE HOUSING Compensator Valve Spring:

Outer Spring

Inner Spring (if used)

LOAD SENSE VALVE HOUSING Compensator Valve Spring

Outer Spring

Inner Spring (if used)

Continued on next page

CTM7 (28FEB97)

-25-6

Radial Piston Pumps 280297

PN=90

3000 Series (HPR) Hydraulic Pump/Specifications

Item

Measurement

Specification

Load Sense Spring Orange

Free Length (approximate) Test Length

73 mm (2.9 in.)

64 mm at 58—70 N (2.5 in. at 13—16 lb force)

Violet

Free Length (approximate) Test Length

73 mm (2.9 in.)

63 mm at 115—139 N (2.4 in. at 26—31 lb force)

Pink

Free Length (approximate) Test Length

75 mm (3.0 in.)

63 mm at 169—205 N (2.4 in. at 38—46 lb force)

Free Length (approximate) Test Length

64 mm (2.5 in.)

59 mm at 180—220 N (2.3 in. at 40—49 lb force)

Crankcase Relief Valve Spring

RX,CTM725,4

CTM7 (28FEB97)

-25-7

25 7

-19-20FEB97

Radial Piston Pumps 280297

PN=91

3000 Series (HPR) Hydraulic Pump/Diagnosing Malfunctions

DIAGNOSING MALFUNCTIONS

25 8

No Pump Output Broken pump drive shaft Pressure compensator valve malfunction Improper compensator valve adjustment Excessive charge circuit leakage No oil to pump inlet Low Pump Output Low deadhead pressure Compensator valve, seat, spring, or packing failure Worn or scored pistons and bores Broken discharge valve or spring Restricted inlet Insufficient inlet oil Hydraulic Functions Slow Low deadhead pressure Plugged hydraulic filter or return filter Compensator valve, seat, spring, or packing failure Slow Pump Response Failure of charge pump or charge leak Plugged return oil filter

Function Chatter Insufficient inlet oil (cavitation) Sticking pump pistons Broken discharge valve or spring Broken inlet valve Charge system leakage Charge pump suction air leak Pump and Oil Line Vibration Broken discharged valve or spring Leaking inlet valve Broken inlet valve Pump Shaft Seal Failure Over-pressurized seal drain line Broken discharge valve Pump Noise or Squeal Low Deadhead pressure Compensator valve, seat, spring, or packing failure Leaking inlet valve Air leak at inlet connections (inspect) Insufficient inlet oil (cavitation)

Excessive Pump Pressure Improper compensator valve adjustment

RX,CTM725,5

CTM7 (28FEB97)

-25-8

-19-17FEB97

Radial Piston Pumps 280297

PN=92

3000 Series (HPR) Hydraulic Pump/Cross-Sectional and Exploded Views

CROSS-SECTION AND EXPLODED VIEW—SINGLE BANK PUMP

R40179

-UN-30NOV88

25 9

1—Pump Housing 2—Piston Plug (8 used) 3—Cooling Pin (8 used) 4—Piston spring (8 used) 5—Piston (8 used) 6—Shims (as required)

7—O-Ring 8—Bearing Cup (2 used) 9—Shaft 10—Discharge Valve (8 used) 11—Sealing Ring 12—Bearing cone (2 used)

13—Spacer (2 used) 14—Thrust Washer (2 used) 15—Bearing Race 16—Needle Rollers (50 used) 17—Spacers (3 used) 18—Inlet Valve (8 used)

19—Discharge Valve Seat (8 used) 20—Snap Ring 21—Oil Seal 22—Discharge Port (S1) 23—Crankcase Port (C1)

Standard Drive Pump

RX,CTM725,6

CTM7 (28FEB97)

-25-9

-19-20FEB97

Radial Piston Pumps 280297

PN=93

3000 Series (HPR) Hydraulic Pump/Cross-Sectional and Exploded Views

CROSS-SECTION AND EXPLODED VIEW—DOUBLE BANK PUMP

R40180

-UN-30NOV88

25 10

1—Primary Housing 2—Piston Plug (16 used) 3—Cooling Pin (16 used) 4—Piston Spring (16 used) 5—Piston (16 used) 6—Secondary Housing

7—O-Ring (2 used) 8—Inlet Housing 9—Shaft 10—Discharge Valve (16 used) 11—Bearing Cup (2 used)

12—Shims (as required) 13—End Plug 14—Sealing Ring 15—Bearing Cone (2 used) 16—Spacer (2 used) 17—Thrust Washer (4 used)

18—Bearing Race (2 used) 19—Needle Rollers (100 used) 20—Spacer (6 used) 21—Inlet Valve (16 used)

Standard Drive Pump

RX,CTM725,7

CTM7 (28FEB97)

-25-10

-19-20FEB97

Radial Piston Pumps 280297

PN=94

3000 Series (HPR) Hydraulic Pump/Cross-Sectional and Exploded Views

CROSS-SECTION AND EXPLODED VIEW—CONTROL VALVE NON-UNITIZED DESIGN

R40184

-UN-30NOV88

25 11

1—Inlet Housing 2—Pressure Compensator Adjusting Screw 3—Bushing With Sleeve 4—Pressure Compensator Outer Spring

5—Pressure Compensator Inner Spring (if used) 6—Spring Guide 7—Pressure Compensator Control Valve

8—Dampening Valve 9—Dampening Valve Spring 10—Shuttle Valve 11—Shuttle Valve Spring

12—Manual Destroke (Optional) 13—Electric Destroke (Optional)

Standard Drive Single Bank

RX,CTM725,8

CTM7 (28FEB97)

-25-11

-19-21FEB97

Radial Piston Pumps 280297

PN=95

3000 Series (HPR) Hydraulic Pump/Cross-Sectional and Exploded Views

CROSS-SECTION AND EXPLODED VIEW—CONTROL VALVE UNITIZED DESIGN—PRESSURE COMPENSATED

R40185

-UN-30NOV88

25 12

1—Inlet Housing 2—Pressure Compensator Housing 3—Pressure Compensator Adjusting Screw

4—Special Plug 5—Pressure Compensator Outer Spring 6—Pressure Compensator Inner Spring (if used)

7—Spring Guide 8—Pressure Compensator Valve 9—Spring

10—Crankcase Relief Valve 11—Spring 12—Shuttle Valve 13—Destroke Port Plug

RX,CTM725,9

CTM7 (28FEB97)

-25-12

-19-21FEB97

Radial Piston Pumps 280297

PN=96

3000 Series (HPR) Hydraulic Pump/Cross-Sectional and Exploded Views

CROSS-SECTION AND EXPLODED VIEW—CONTROL VALVE UNITIZED DESIGN—LOAD SENSING

R40186

-UN-30NOV88

25 13

1—Inlet Housing 2—Load Sense Housing 3—Pressure Compensator Adjusting screw 4—Special Plug 5—Pressure Compensator Outer Spring

6—Pressure Compensator Inner Spring (if used) 7—Spring Guide 8—Pressure Compensator Valve

9—Pin 10—Spring 11—Crankcase Relief Valve 12—Special Plug 13—Shims (as required)

14—Pin 15—Spring 16—Spring Guide 17—Load Sense Valve

RX,CTM725,10

CTM7 (28FEB97)

-25-13

-19-21FEB97

Radial Piston Pumps 280297

PN=97

3000 Series (HPR) Hydraulic Pump/Piston Assemblies

REMOVE AND INSPECT PISTON ASSEMBLIES

-UN-22JAN90

IMPORTANT: Pistons must be installed in their original bores if they are reused. Write numbers on piston plugs and discharge valve plugs for identification.

R39493

1. Remove piston assemblies and place in a parts tray to insure installation into the same bores from which assemblies were removed.

2. Inspect piston plugs (A) for thread damage.

3. Inspect face and skirt of pistons (F). Replace all pistons and pump housing(s) if metal transfer, galling, or scoring exists.

IMPORTANT: All springs must be the same color code.

A—Piston Plug B—O-Ring C—Shield D—Cooling Pin E—Spring F—Piston

4. Inspect springs (E). Replace ALL piston springs as a set.

NEW SPRING SPECIFICATION Free Length (approximate) . . . . . . . . . . . . . . . . . . . 77 mm (3.0 in.)

Test Length . . . . . . . . . . . . . . . . . . . . . . . 54.4 mm at 241—295 N (2.1 in. at 54—66 lb force)

RX,CTM725,11

-19-17FEB97

RX,CTM725,12

-19-17FEB97

INSTALL PISTON ASSEMBLIES 1. Install new O-rings and plastic shields on piston plugs.

-UN-22JAN90

IMPORTANT: To prevent damage to O-rings and shields, DO NOT use an air-operated wrench to tighten piston plugs; use a torque wrench.

2. Install piston assemblies. For easier assembly, turn pump shaft so piston installed is on the low side of cam.

R39490

25 14

3. Tighten piston plugs to 200 N·m (150 lb-ft).

CTM7 (28FEB97)

-25-14

Radial Piston Pumps 280297

PN=98

3000 Series (HPR) Hydraulic Pump/Check Shaft End Play

CHECK SHAFT END PLAY 1. Remove piston assemblies. (See Remove and Inspect Piston Assemblies, this group.)

-UN-22JAN90

25 15

NOTE: Use vice grip with curved jaw for better clamping.

R39491

2. Install vice grips as tightly as possible on pump shaft approximately 5/8 in. from housing hub.

3. Put a dial indicator base on pump housing and indicator contact point on steel ball placed in center of pump shaft.

4. Turn shaft back and forth while pushing down to align the tapered roller bearings inside pump housing.

RX,CTM725,13

-19-17FEB97

RX,CTM725,14

-19-17FEB97

5. Zero the indicator.

6. Pry upward on vice grips using a long (3/4 in. minimum) box-end wrench noting indicator reading. If end play is more than specification, check bearings for wear.

END PLAY SPECIFICATION Acceptable . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.025—0.100 mm (0.001—0.004 in.)

R39492

-UN-22JAN90

7. Increase number or size of shims in inlet housing on single bank pump to obtain correct specification.

CTM7 (28FEB97)

-25-15

Radial Piston Pumps 280297

PN=99

3000 Series (HPR) Hydraulic Pump/Pump Shaft For DOUBLE BANK pump, perform Steps 7a and 7b.

-UN-22JAN90

IMPORTANT: Double bank pump bearing cup removal in secondary housing will damage shims. DO NOT remove bearing cup if end play is within specification and cup does not appear to be worn or damaged.

NOTE: On double bank pump with “B” drive, remove bearing cup and shims using a bearing cup puller.

R39502

25 16

7a. Drive end plug through secondary housing on double bank pump to remove bearing cup and shims.

7b. Increase number or size of shims in secondary housing to obtain correct specification.

RX,CTM725,15

-19-17FEB97

RX,CTM725,16

-19-17FEB97

REMOVE AND INSTALL PUMP SHAFT IMPORTANT: Pistons must be installed in their original bores if they are reused.

1. Remove piston assemblies. (See Remove and Inspect Piston Assemblies, this group.)

2. Remove secondary pump housing on double bank pump.

3. Remove inlet housing from primary pump housing.

(See Remove and Install Inlet Housing, this group.)

CTM7 (28FEB97)

-25-16

Radial Piston Pumps 280297

PN=100

3000 Series (HPR) Hydraulic Pump/Pump Shaft 4. Remove pump shaft assembly (A) on single bank pump using a hammer to remove bearing cup. Lift shaft from primary housing on double bank pump.

R39495

-UN-22JAN90

25 17

RX,CTM725,17

-19-17FEB97

RX,CTM725,18

-19-17FEB97

RX,CTM725,19

-19-17FEB97

5. Replace oil seal in primary pump housing before installing pump shaft. (See Remove and Install Oil Seal, this group.)

R39605

-UN-22JAN90

6. Install pump shaft in primary pump housing using JDG494 Spline Protector to prevent seal damage.

R39606

-UN-22JAN90

7. Install bearing cup on single bank pump leaving cup partially away from bearing cone. Installation of shims and inlet housing will correctly align bearing cup and cone.

CTM7 (28FEB97)

-25-17

Radial Piston Pumps 280297

PN=101

3000 Series (HPR) Hydraulic Pump/Pump Shaft

DISASSEMBLE AND INSPECT PUMP SHAFT 1. Visually inspect taper bearing cones (A).

-UN-22JAN90

2. Visually inspect fixed spacers (B) and thrust washers (D).

R39499

3. Inspect race (C) for nicks, scratches, pitting or metal discoloration. Replace race and pistons if external damage exists.

4. Hold pump shaft and slowly turn race (C). If assembly is sticking or noisy, replace ALL needle rollers between race and pump journal.

A—Bearing Cones B—Fixed Spacers

C—Race D—Thrust Washers

RX,CTM725,20

-19-17FEB97

RX,CTM725,21

-19-21FEB97

IMPORTANT: Be careful not to scratch or damage machined shaft surface (A). This could cause seal leakage.

-UN-22JAN90

5. Remove sealing ring(s) from shaft using a JDH6 O-ring Seal Hook.

R39945

25 18

CTM7 (28FEB97)

-25-18

Radial Piston Pumps 280297

PN=102

3000 Series (HPR) Hydraulic Pump/Pump Shaft For “B” DRIVE COUPLER, perform Steps 5a, 5b, 5c, 5d, 5e, 5f and 5g.

25 19 -UN-09MAR90

5a. Inspect coupler splines (A).

RW16736

IMPORTANT: Do not remove coupler from shaft unless absolutely necessary. Coupler will have to be removed in order to remove rear bearing cone on pump shaft and rear bearing race assembly on double bank pump shaft.

NOTE: Machine screws should be ground on the ends so shaft length of screws are 7.9 mm (5/16 in.) long. This is important when compressing snap ring during coupler removal.

5b. Insert a No. 2 or No. 3 machine screw 3/8 in. long into each of the five holes (B) in coupler. Check for snap ring spring-back by pushing on screw while pushing coupler toward bearing. Snap ring must be under all five holes before coupler can be removed.

NOTE: Skip Step 5c and 5d if snap ring is under all five holes.

RX,CTM725,22

-19-25FEB97

RX,CTM725,23

-19-25FEB97

5c. Mark hole (1) where snap is not present.

-UN-09MAR90

5d. Put screws in holes (2) and (4) and use the following push-release sequence to make snap ring “walk around” internal groove: PUSH-RELEASE SEQUENCE

RW16737

1—Push 2 2—Push 4 3—Release 2 4—Release 4

Continue sequence until snap ring is under all five holes in coupler.

CTM7 (28FEB97)

-25-19

Radial Piston Pumps 280297

PN=103

3000 Series (HPR) Hydraulic Pump/Pump Shaft

-UN-09MAR90

5f. Pry coupler off end of shaft while snap ring is compressed.

RW16738

5g. Inspect internal splines of coupler. Replace snap ring as required.

RX,CTM725,24

-19-17FEB97

RX,CTM725,25

-19-17FEB97

RX,CTM725,26

-19-17FEB97

6. Remove bearing cones using a bearing puller.

7. Disassemble pump shaft assembly.

-UN-22JAN90

8. Inspect shoulder surface (A) of taper roller bearings.

Replace if spacer wear exists.

R39504

9. Inspect fixed spacers (B). Replace if scored or discolored.

10. Inspect pump shaft journal (C). Replace if pitted, scored, or discolored.

11. Inspect thrust washers (A) for cracking or chipping.

Inspection may require magnification.

-UN-22JAN90

12. Inspect spacers (B). Replace if scored or discolored.

13. Inspect race (C). Replace if scored or discolored.

14. Inspect needle rollers (D). Replace ALL needle rollers if any are scratched, pitted or discolored.

R39505

25 20

5e. Compress snap ring in coupler by installing No. 2 or No. 3 machine screws in each of the five holes in coupler. Use a piece of metal strapping material and a hose clamp to compress snap ring.

A—Thrust Washers B—Spacers C—Race D—Needle Rollers

CTM7 (28FEB97)

-25-20

Radial Piston Pumps 280297

PN=104

3000 Series (HPR) Hydraulic Pump/Pump Shaft

ASSEMBLE PUMP SHAFT IMPORTANT: DO NOT use grease to hold needle rollers. Doing so can restrain roller movement and cause pump failure. Use only clean hydraulic oil.

-UN-22JAN90

25 21

R39600

Fixed spacers on double bank pump are installed only after races are installed on pump shaft. One fixed spacer is used between each race and taper roller bearing.

1. Put spacer on pump shaft.

2. Install first row needle rollers (25 used) on shaft journal using a rubber band to aid installation.

3. Install race with thrust washers onto pump shaft sliding race over first row needle rollers. Pull rubber band over race as race slides over needle rollers.

RX,CTM725,27

-19-20FEB97

RX,CTM725,28

-19-17FEB97

4. Install middle spacer in race and second row of needle rollers (25 used).

-UN-22JAN90

5. Install third spacer over second row of needle rollers.

6. Install fixed spacer on pump shaft.

R39601

IMPORTANT: Taper roller bearings must be pressed onto pump shaft even if shaft has not been disassembled. This assures correct pump shaft end play.

7. Press bearing cones against pump shaft journal making sure fixed spacer aligns correctly with slot in shaft journal.

CTM7 (28FEB97)

-25-21

Radial Piston Pumps 280297

PN=105

3000 Series (HPR) Hydraulic Pump/Pump Shaft For “B ” DRIVE COUPLER, perform Steps 7a, 7b, and 7c.

-UN-09MAR90

7a. Install snap ring on pump shaft groove.

7b. Install coupler on end of shaft using a JDH6 O-ring Seal Hook to compress snap ring (A) while pushing on coupler.

RW16739

7c. Install new sealing ring (B) on coupler using procedure in Steps 8, 9, and 10.

RX,CTM725,29

-19-21FEB97

RX,CTM725,30

-19-25FEB97

8. Install JDG494 Spline Protector Tool (C) on pump shaft.

-UN-02FEB90

9. Carefully slide new sealing ring (B) over spline protector and down into groove on pump shaft making sure sealing ring does not twist. Use JDG493 Pump Shaft Seal Sizer (A) to aid installation.

R37912

NOTE: JDG493 Pump Shaft Seal Sizer may be used in place of hose clamp.

-UN-22JAN90

10. Clamp sealing ring in groove using a hose clamp.

Put shim stock between clamp and sealing ring to prevent sealing ring damage. Leave hose clamp in place approximately five minutes to allow sealing ring to set.

R39604

25 22

CTM7 (28FEB97)

-25-22

Radial Piston Pumps 280297

PN=106

3000 Series (HPR) Hydraulic Pump/Shaft Seals

INSPECT BEARING CUPS IMPORTANT: Bearing cups must be used with the same cone.

-UN-22JAN90

25 23

Pump housing, bearing cones and cups must be replaced if bearing cups show signs of spinning.

R39503

NOTE: Bearing cup removal from secondary housing on double bank pump will damage shims. New shims must be used if bearing cup is removed.

1. Inspect bearing cups.

2. Put bearing cup on cone and turn slowly. If bearing makes a clicking noise or is sticking, clean and dip cone in clean hydraulic oil. Turn again and replace bearing cone and cup if bearing continues to click or stick.

RX,CTM725,31

-19-20FEB97

RX,CTM725,32

-19-20FEB97

RX,CTM725,33

-19-20FEB97

INSPECT PUMP HOUSING

-UN-22JAN90

1. Inspect piston bores (A) in pump housing. Replace housing and pistons if scoring, galling or metal transfer exists.

R39506

2. Install each piston (B) into the piston bore so piston extends approximately 13 mm (0.5 in.) into crankcase after visual inspection. Pistons must slide smoothly and have no side play. If any side play is found, replace housing and pistons.

REMOVE AND INSTALL SHAFT SEAL

-UN-22JAN90

NOTE: Through drive shaft has an shaft oil seal on both ends of pump.

1. Remove seal retaining snap ring(s).

R39512

2. Remove shaft seal(s) using a puller and slide hammer.

CTM7 (28FEB97)

-25-23

Radial Piston Pumps 280297

PN=107

3000 Series (HPR) Hydraulic Pump/Shaft Seals

-UN-09MAR90

NOTE: Use a 1-15/16 in. disk to aid installation.

3. Install shaft seal (A) with lip (spring side) toward inside of pump housing making sure drain passage is not blocked.

T85279

25 24

IMPORTANT: DO NOT push seal beyond inner edge of snap ring groove. Doing so can close drain passage and cause a seal failure.

4. Apply petroleum jelly to lips of seal(s) for lubrication when shaft is installed.

5. Install retaining snap ring(s).

RX,CTM725,34

CTM7 (28FEB97)

-25-24

-19-20FEB97

Radial Piston Pumps 280297

PN=108

3000 Series (HPR) Hydraulic Pump/Discharge Valves and Seats

REMOVE, INSPECT, AND INSTALL DISCHARGE VALVES

25 25 -UN-22JAN90

1. Remove inlet housing on single bank pump or secondary housing and inlet housing on double bank pump. (See Remove and Install Inlet Housing, this group.)

R39508

IMPORTANT: Discharge valve assemblies must be installed in the original bores.

2. Remove discharge valve assemblies and put in a parts tray to insure installation into the same bores from which valves were removed.

3. Inspect valve guide (A) for fatigue cracks at tabs and radius of legs.

4. Inspect discharge valve plug (D) for thread damage or wear on stop.

A—Valve Guide B—Discharge Valve C—Spring D—Discharge Valve Plug E—O-Ring

5. Inspect springs (C). Replace as required.

NEW SPRING SPECIFICATION Free Length (approximate) . . . . . . . . . . . . . . . . . . 12.7 mm (0.5 in.)

Test Length . . . . . . . . . . . . . . . . . . . . . . . . . 9.3 mm at 17—24 N (0.4 in. at 4—5 lb force)

6. Inspect valve (B) for erosion, pitting or excessive wear. Replace valve if wear is excessive. Discharge valve seat should also be checked for wear. (See Inspect, Remove, and Install Discharge Valve Seats, this group.)

RX,CTM725,35

-19-20FEB97

RX,CTM725,36

-19-17FEB97

R39507

-UN-22JAN90

7. Install discharge valve assemblies with new O-rings.

Tighten discharge valve plugs to 104 N·m (100 lb-ft).

CTM7 (28FEB97)

-25-25

Radial Piston Pumps 280297

PN=109

3000 Series (HPR) Hydraulic Pump/Inlet Valves

INSPECT, REMOVE, AND INSTALL DISCHARGE VALVE SEATS

-UN-22JAN90

1. Wipe discharge valve seats (A) with your finger accessing seat through the discharge valve bores. This should be done before inspection since oil on valve seat may give impression of seat damage.

R39509

2. Visually inspect discharge valve seats (A) for peening or damage.

IMPORTANT: Press fit is critical for sealing, DO NOT remove discharge valve seats unless replacement is absolutely necessary.

3. Install special screw into seat through piston bore and JDG539 Installer and Removal Tool through discharge valve bore.

4. Install a slide hammer and adapter into the tool and remove seat.

RX,CTM725,37

-19-17FEB97

RX,CTM725,38

-19-17FEB97

RX,CTM725,39

-19-17FEB97

R39597

-UN-22JAN90

5. Install new discharge valve seat (A) using JDG539 Installer and Removal Tool (B). Drive seat into housing until flange of tool is against face of housing.

INSPECT, REMOVE, AND INSTALL INLET VALVES

-UN-22JAN90

1. Check inlet valves for smooth movement and valve lift. Valve should move until retainer contacts valve body.

If valves are not broken and move smoothly, do not remove.

R39510

25 26

CTM7 (28FEB97)

-25-26

Radial Piston Pumps 280297

PN=110

3000 Series (HPR) Hydraulic Pump/Inlet Housing IMPORTANT: Removed inlet valves must be replaced with new valves, since press fit is critical for sealing.

25 27

R39511

-UN-22JAN90

2. Remove inlet valves and discard.

RX,CTM725,40

-19-17FEB97

RX,CTM725,41

-19-17FEB97

RX,CTM725,42

-19-17FEB97

R39598

-UN-22JAN90

3. Install new inlet valve assemblies using a socket.

Drive valves into pump housing until valves are flush with housing surface.

REMOVE AND INSTALL INLET HOUSING

-UN-22JAN90

NOTE: Packing designs are different for non-unitized versus unitized pumps. Double bank pump has special packings on both sides of inlet housing.

1. Remove secondary housing on double bank pump.

R39494

2. Remove inlet housing from pump housing. Save shims (B) on single bank pumps for reassembly.

3. Discard special packings (A) and O-ring (C).

CTM7 (28FEB97)

-25-27

Radial Piston Pumps 280297

PN=111

3000 Series (HPR) Hydraulic Pump/Inlet Housing For pump with AUXILIARY GEAR-DRIVEN CHARGE PUMP, perform Steps 3a and 3b.

-UN-22JAN90

3a. Install new charge pump drive seal in inlet housing.

R39608

IMPORTANT: DO NOT move pump until inlet housing and charge pump have been installed.

Doing so may cause drive key in end of pump shaft to become dislodged.

-UN-22JAN90

3b. Inspect special key (A) and install into end of pump shaft.

R39610

25 28

RX,CTM725,43

CTM7 (28FEB97)

-25-28

-19-17FEB97

Radial Piston Pumps 280297

PN=112

3000 Series (HPR) Hydraulic Pump/Pressure Compensator Valve—Non-Unitized For SINGLE BANK pump, perform Step 3c.

3c. Install shims (C) in inlet housing using a small amount of petroleum jelly to hold shims in position.

-UN-22JAN90

25 29

4. Install special packings (A) and (B) and O-ring on center hub of pump housing, using small amount of petroleum jelly to hold packings in position.

R39607

CAUTION: Failure to align the high-pressure passages will keep the pump in full stroke.

This could result in hydraulic system damage and possible a high-pressure leak which could create a risk of personal injury.

5. Install inlet housing making sure high-pressure passage (B) in inlet housing and primary pump housing are aligned.

6. Install secondary housing on double bank pump making sure high-pressure passages align.

7. Install cap screws and tighten cap screws alternately to 200 N·m (150 lb-ft).

RX,CTM725,44

-19-17FEB97

RX,CTM725,45

-19-20FEB97

DISASSEMBLE, INSPECT, AND ASSEMBLE PRESSURE COMPENSATOR VALVE— NON-UNITIZED DESIGN -UN-22JAN90

NOTE: Inlet housing does not have to be removed from pump for servicing pressure compensator.

CTM7 (28FEB97)

-25-29

R39611

1. Remove electric destroke solenoid (A) from inlet housing, if so equipped, to prevent damage to solenoid during pressure compensator valve repair.

Radial Piston Pumps 280297

PN=113

3000 Series (HPR) Hydraulic Pump/Pressure Compensator Valve—Non-Unitized 2. Remove adjusting screw (A) and sleeve assembly (B) by first loosening nut (C).

RW16716

-UN-09MAR90

NOTE: Several adjusting screw assemblies exist.

RX,CTM725,46

-19-17FEB97

RX,CTM725,47

-19-25FEB97

-UN-09MAR90

IMPORTANT: Pump pressure adjusting screw assembly WITHOUT spring sleeve is not serviceable. Pressure compensator should be updated to design with spring sleeve. Kits are available.

-UN-09MAR90

RW16717

NOTE: Two spring sleeve designs exist. Spring and sleeve assemblies with a single row of holes (A) are NOT serviceable and should be updated to the design with two rows of holes (B). Kits are available.

RW16718

25 30

CTM7 (28FEB97)

-25-30

Radial Piston Pumps 280297

PN=114

3000 Series (HPR) Hydraulic Pump/Pressure Compensator Valve—Non-Unitized NOTE: Not all pressure adjusting assemblies will use the smaller inner spring (C).

25 31 -UN-09MAR90

3. Inspect springs (B) and (C).

NEW SPRING SPECIFICATION

No Color Free Length (approximate) . . . . . . . . . . . . . . . . . 97 mm (3.8 in.)

Test Length . . . . . . . . . . . . . . . . . . . . . 78mm at 1340—1640 N (3.1 in. at 300—370 lb force) Green Free Length (approximate) . . . . . . . . . . . . . . . . . 96 mm (3.7 in.)

Test Length . . . . . . . . . . . . . . . . . . . . . . . . . . . 82mm at 780 N (3.2 in. at 175 lb force) Inner Spring (if used): Free Length (approximate) . . . . . . . . . . . . . . . . . . 92 mm (3.6 in.)

Test Length . . . . . . . . . . . . . . . . . . . . . . . 79 mm at 495—605 N (3.1 in. at 110—135 lb force)

RW16719

Outer Spring:

A—Sleeve Assembly B—Outer Spring C—Inner Spring D—Spring Guide

4. Inspect guide (D).

RX,CTM725,48

-19-17FEB97

RX,CTM725,49

-19-17FEB97

RX,CTM725,50

-19-17FEB97

NOTE: Inlet housing is shown with electric destroke solenoid removed.

-UN-22JAN90

5. Remove and inspect pressure compensator plug (A), dampening spring (B) and valve (C).

NEW SPRING SPECIFICATION

R39614

Free Length (approximate) . . . . . . . . . . . . . . . . . . 20.6 mm (0.8 in.)

Test Length . . . . . . . . . . . . . . . . . . . . . . . 13.7 mm at 200—247 N (0.5 in. at 45—55 lb force)

-UN-22JAN90

6. Install small end of DFRW52 Pressure Compensator Valve Installation and Removal Tool (A) in center of valve assembly inside inlet housing. (See Dealer Fabricated Tools, Group 99.)

R39615

7. Carefully push on tool removing pressure compensator valve assembly (B).

CTM7 (28FEB97)

-25-31

Radial Piston Pumps 280297

PN=115

3000 Series (HPR) Hydraulic Pump/Pressure Compensator Valve—Non-Unitized

-UN-22JAN90

IMPORTANT: All pressure compensator parts must be thoroughly cleaned. All passage holes in parts must be open and clean.

R39616

Valve (A) and sleeve (B) must be assembled correctly. Assembling incorrectly will cause pump malfunction.

9. Install new back-up (C) and O-Ring (D) with back-up ring towards center of valve sleeve.

-UN-22JAN90

10. Carefully install valve assembly into housing using DFRW52 Pressure Compensator Valve Installation and Removal Tool. Push until valve bottoms out in housing.

Scribe line on tool should be approximately even with opening in inlet housing.

R39620

A—Valve B—Sleeve C—Back-Up Ring D—O-Ring

RX,CTM725,51

-19-20FEB97

RX,CTM725,52

-19-17FEB97

-UN-22JAN90

11. Install retaining plug (A) with new O-ring, spring (B) and valve (C) into inlet housing tightening retaining plug to 140 N·m (100 lb-ft).

R39614

25 32

8. Inspect pressure compensator valve assembly.

Valve (A) must slide smoothly in sleeve (B). Replace assembly if valve sticks in sleeve.

CTM7 (28FEB97)

-25-32

Radial Piston Pumps 280297

PN=116

3000 Series (HPR) Hydraulic Pump/Pressure Compensator Valve—Non-Unitized 12. Install pressure adjusting assembly into inlet housing making sure spring guide protrusion is toward spring(s).

25 33 -UN-22JAN90

IMPORTANT: Adjusting screw should be set to a minimum depth to prevent excessive deadhead pressure at start up.

R39698

13. Check pump deadhead pressure setting. (See 3000 Series Operation and Tests, Group 115.)

RX,CTM725,53

-19-17FEB97

RX,CTM725,54

-19-20FEB97

DISASSEMBLE, INSPECT, AND ASSEMBLE SHUTTLE VALVE—NON-UNITIZED DESIGN

-UN-22JAN90

NOTE: Some pumps may be equipped with an optional manual destroke or optional electric destroke solenoid in place of the destroke plug.

R39617

1. Remove destroke plug (A) or optional manual destroke or electric destroke solenoid.

2. Remove and inspect shuttle valve (B) and spring (C).

NEW SPRING SPECIFICATION Free Length (approximate) . . . . . . . . . . . . . . . . . . . 45 mm (1.8 in.)

Test Length . . . . . . . . . . . . . . . . . . . . . . . 26.5 mm at 175—218 N (1.0 in. at 40—49 lb force)

3. Install spring (C) and shuttle valve (B) depressing valve against spring to insure free travel.

4. Install destroke plug, manual destroke or electric destroke solenoid. (See Inspect and Install Destroke Plug, Manual Destroke or Electric Destroke Solenoid, this group.)

CTM7 (28FEB97)

-25-33

Radial Piston Pumps 280297

PN=117

3000 Series (HPR) Hydraulic Pump/Pressure Compensator Valve—Unitized

INSPECT AND INSTALL DESTROKE PLUG, MANUAL DESTROKE, OR ELECTRIC 25 DESTROKE SOLENOID -UN-30NOV88

1. Discard O-rings (A) and (B) and back-up ring (C) from destroke plug, manual destroke or electric destroke solenoid.

R39618

2. Inspect manual destroke or electric destroke for damage. Small hole(s) should be open.

IMPORTANT: Torque specification for electric destroke solenoid is different than destroke plug or manual destroke. Over torquing electric destroke solenoid may cause pump to malfunction.

3. Install electric destroke solenoid, manual destroke or destroke plug and tighten to specification.

TORQUE SPECIFICATION Manual Destroke Screw or Destroke plug . . . . . . . . . . . . . . . . . . . . . . . . . . 61 N·m (45 lb-ft) Electric Destroke Solenoid . . . . . . . . . . . . . . . . . . 34 N·m (25 lb-ft)

RX,CTM725,55

-19-20FEB97

RX,CTM725,56

-19-20FEB97

REMOVE AND INSTALL VALVE HOUSING— UNITIZED DESIGN

-UN-19MAY89

1. Remove valve housing from inlet housing.

2. Inspect valve housing and inlet housing surfaces.

Surfaces must be clean.

3. Replace all pressure packings (A).

RW16733

34

IMPORTANT: Valve housing must be installed with shims on each cap screw. Cap screws must not be over-tightened.

4. Install valve housings with shims (B). Tighten cap screws to 15 N·m (11 lb-ft).

CTM7 (28FEB97)

-25-34

Radial Piston Pumps 280297

PN=118

3000 Series (HPR) Hydraulic Pump/Pressure Compensator Valve—Unitized

DISASSEMBLE, INSPECT, AND ASSEMBLE PRESSURE COMPENSATOR VALVE— UNITIZED DESIGN

25 35 -UN-30NOV88

NOTE: Valve housing does not have to be removed from inlet housing for servicing.

R40195

1. Remove electric destroke solenoid from valve housing, if so equipped, to prevent damage to solenoid during valve repair.

2. Slowly loosen and remove pressure adjusting screw (A), also removing washer (B), spring(s) (C) and spring guide (D).

A—Pressure Adjusting Screw B—Washer C—Spring(s) D—Spring Guide

3. Inspect parts (A—D).

NEW SPRING SPECIFICATION Outer Spring: Red Free Length (approximate) . . . . . . . . . . . . . . . . . . 71mm (2.8 in.)

Test Length . . . . . . . . . . . . . . . . . . . . . . . 60mm at 580—700 N (2.4 in. at 130—158 lb force) Blue Free Length (approximate) . . . . . . . . . . . . . . . . . . 71mm (2.8 in.)

Test Length . . . . . . . . . . . . . . . . . . . . . . . . . . . 60mm at 930 N (2.4 in. at 210—254 lb force) Inner Spring (if used): Free Length (approximate) . . . . . . . . . . . . . . . . . . 69 mm (2.7 in.)

Test Length . . . . . . . . . . . . . . . . . . . . . . . 58 mm at 270—330 N (2.3 in. at 60—74 lb force)

RX,CTM725,57

CTM7 (28FEB97)

-25-35

-19-20FEB97

Radial Piston Pumps 280297

PN=119

3000 Series (HPR) Hydraulic Pump/Pressure Compensator Valve—Unitized

-UN-30NOV88

4. Remove plug (A) from housing and check for smooth back and forth movement of pressure compensator valve (B). If valve sticks, thoroughly clean valve and internal valve passage in housing. Dip valve in clean hydraulic oil and recheck for smooth valve movement. If valve continues to stick, valve housing assembly must be replaced.

R40196

25 36

NOTE: Insert a brass dowel through the adjusting spring end of housing to aid in checking valve movement.

IMPORTANT: Adjusting screw should be set to a minimum depth to prevent excessive deadhead pressure at start up.

5. Install pressure compensator valve and pressure adjusting assembly using new O-rings on adjusting plug and valve plug.

6. Check pump deadhead pressure setting. (See 3000 Series Operation and Tests, Group 115.)

RX,CTM725,58

CTM7 (28FEB97)

-25-36

-19-20FEB97

Radial Piston Pumps 280297

PN=120

3000 Series (HPR) Hydraulic Pump/Pressure Compensator Valve—Unitized

DISASSEMBLE, INSPECT, AND ASSEMBLE CRANKCASE RELIEF VALVE— UNITIZED DESIGN

25 37 -UN-23JAN90

NOTE: Pressure Compensator Housing and Load Sense Housing use two different crankcase relief valve designs. Valve function is the same.

R40197

For pumps equipped with Pressure Compensator Housing, perform Steps 1, 2, 3, and 4.

1. Remove parts (A—E) for standard crankcase relief valve assembly or parts (A), (E), and (F) for external control valve assembly.

2. Inspect parts.

-UN-09MAR90

NEW SPRING SPECIFICATION

3. Install spring (E) and crankcase relief valve (D) or external control valve (F) in housing and check for smooth valve movement. If valve sticks, thoroughly clean valve and valve bore in housing. Dip valve in clean hydraulic oil and recheck for smooth valve movement. If valve continues to stick, replace valve.

RW16735

Spring (C) Free Length (approximate) . . . . . . . . . . . . . . . . . . . 44mm (1.7 in.)

Test Length . . . . . . . . . . . . . . . . . . . . . . . . . 22mm at 18—22 N (0.9 in. at 4—5 lb force) Spring (E) Free Length (approximate) . . . . . . . . . . . . . . . . . . . 51mm (2.0 in.)

Test Length . . . . . . . . . . . . . . . . . . . . . . . . 37mm at 200—245 N (1.5 in. at 45—55 lb force)

A—Destroke Plug B—Shuttle Valve C—Spring D—Crankcase Relief Valve E—Spring F—External Control Valve

NOTE: New O-rings and backup rings should be installed on destroke plug, manual destroke or destroke solenoid. Torque specification for destroke solenoid is different than plug or manual destroke. (See Inspect and Install Destroke Plug, Manual Destroke or Electric Destroke Solenoid in this group.)

4. Reassemble valve assembly.

RX,CTM725,59

CTM7 (28FEB97)

-25-37

-19-20FEB97

Radial Piston Pumps 280297

PN=121

3000 Series (HPR) Hydraulic Pump/Pressure Compensator Valve—Unitized For pumps equipped with Load Sense Housing perform Steps 1a, 2a, 3a, and 4a.

-UN-23JAN90

1a. Remove plug (A), pin (B), spring (C) and crankcase relief valve (D).

2a. Inspect parts (A—D).

NEW SPRING SPECIFICATION

R40198

25 38

Free Length (approximate) . . . . . . . . . . . . . . . . . . . 64 mm (2.5 in.)

Test Length . . . . . . . . . . . . . . . . . . . . . . . . 59 mm at 180—220 N (2.3 in. at 40—49 lb force)

NOTE: Checking smooth valve movement can be accomplished by manipulating valve through ports on bottom of housing.

A—Plug B—Pin C—Spring D—Crankcase Relief Valve

3a. Install crankcase relief valve in housing and check for smooth valve movement. If valve sticks, thoroughly clean valve and crankcase relief passage in housing. Dip valve in clean hydraulic oil and recheck for smooth valve movement. If valve continues to stick, replace valve.

4a. Reassemble crankcase relief valve assembly.

RX,CTM725,60

CTM7 (28FEB97)

-25-38

-19-20FEB97

Radial Piston Pumps 280297

PN=122

3000 Series (HPR) Hydraulic Pump/Pressure Compensator Valve—Unitized

DISASSEMBLE, INSPECT, AND ASSEMBLE LOAD SENSE VALVE— UNITIZED DESIGN

25 39 -UN-23JAN90

NOTE: Load sense valve is not used on all unitized valve assemblies.

1. Remove load sense parts (A—E).

R40199

2. Inspect parts.

NEW SPRING SPECIFICATION Orange Free Length (approximate) . . . . . . . . . . . . . . . . . . . 73mm (2.9 in.)

Test Length . . . . . . . . . . . . . . . . . . . . . . . . . 64mm at 58—70 N (2.5 in. at 13—16 lb force) Violet Free Length (approximate) . . . . . . . . . . . . . . . . . . . 73mm (2.9 in.)

Test Length . . . . . . . . . . . . . . . . . . . . . . . 63 mm at 115—139 N (2.4 in. at 26—31 lb force) Pink Free Length (approximate) . . . . . . . . . . . . . . . . . . 75 mm (3.0 in.)

Test Length . . . . . . . . . . . . . . . . . . . . . . . 63 mm at 169—205 N (2.4 in. at 38—46 lb force)

A—Load Sense Plug B—Shims C—Pin D—Spring E—Spring Guide

RX,CTM725,61

-19-20FEB97

RX,CTM725,62

-19-20FEB97

NOTE: Insert a brass dowel through spring end of housing to aid in checking valve movement.

R40200

-UN-23JAN90

3. Remove plug (A) from housing and check for smooth back and forth movement of load sense valve (B). If valve sticks, thoroughly clean valve and internal valve passage in housing. Dip valve in clean hydraulic oil and recheck for smooth movement. If valve continues to stick, load sense housing assembly must be replaced.

NOTE: A small amount of petroleum jelly on spring and spring guide will aid in assembling load sense valve assembly.

4. Install load sense valve, spring guide, spring, pin and the correct number of shims.

5. Install plugs with new O-rings.

CTM7 (28FEB97)

-25-39

Radial Piston Pumps 280297

PN=123

3000 Series (HPR) Hydraulic Pump/Pressure Compensator Valve—Unitized

25 40

CTM7 (28FEB97)

-25-40

Radial Piston Pumps 280297

PN=124

Group 30

Auxiliary Charge Pump-2000 and 3000 Series ESSENTIAL OR RECOMMENDED TOOLS NOTE: Order tools from the U.S. SERVICE-GARD™ or European Microfiche Tool Catalogs.

RECOMMENDED TOOLS, as noted, are suggested to perform the job correctly. Some tools may be available from local suppliers or may be fabricated.

30 1

ESSENTIAL TOOLS listed are required to perform the job correctly and are obtainable only from SERVICE-GARD or European Tool Catalogs.

RW25637

RX,TOOLS

-19-21APR94

RX,JDH6

-19-17FEB97

-UN-19FEB97

O-Ring Seal Hook . . . . . . . . . . . . . . . . . . . . . JDH6* Remove and install O-ring seals * RECOMMENDED TOOL

SPECIFICATIONS Item

Measurement

Specification

Charge Pump-to-Compensator Housing—(2000 Series)

Torque

115 N·m (85 lb-ft)

Long Cap Screws

Torque

200 N·m (150 lb-ft)

Short Cap Screw

Torque

115 N·m (85 lb-ft)

Gear

OD (allowable)

43.231 mm (1.7020 in.)

Gear

Length (allowable)

44.805 mm (1.7639 in.)

Gear

Side Clearance (allowable)

0.15 mm (0.006 in.)

Gear

End Clearance (allowable)

0.25 mm (0.010 in.)

Charge Pump-to-Inlet Housing—(3000 Series)

RX,CTM730,1

CTM7 (28FEB97)

-30-1

-19-20FEB97

Radial Piston Pumps 280297

PN=125

Auxiliary Charge Pump-2000 and 3000 Series/Auxiliary Charge Pump

DISASSEMBLE AND INSPECT AUXILIARY CHARGE PUMP

-UN-22JAN90

NOTE: Drive gear shaft length is different for 2000 Series auxiliary charge pump.

R39640

IMPORTANT: DO NOT move 3000 Series hydraulic pump and inlet housing assembly with auxiliary charge pump removed. Doing so could dislodge key in end of pump shaft inside inlet housing causing hydraulic pump failure.

1. Carefully remove auxiliary charge pump from control valve housing.

2. Inspect surfaces (A) for damage that could cause oil leakage.

NOTE: O-ring packing extrusion may be caused by a loosened pressure compensator housing cap screw.

3. Discard O-ring packing (B) and seal (C) inside control valve housing.

RX,CTM730,2

-19-17FEB97

RX,CTM730,3

-19-17FEB97

4. Inspect drive gear shaft bearing area (A).

-UN-22JAN90

5. Inspect bushing (B). Install new gear if bushing requires replacement.

6. Inspect gear face (C).

7. Inspect gear tooth tip (D) for knife edge and rolled tip.

Replace gears as a set if this condition exists.

R39628

30 2

8. Inspect gear tooth contact area (E). Replace gears as a set if this condition is found.

A—Bearing Area B—Bushing C—Gear Face D—Gear Tooth Tip

CTM7 (28FEB97)

-30-2

Radial Piston Pumps 280297

PN=126

Auxiliary Charge Pump-2000 and 3000 Series/Auxiliary Charge Pump 9. Measure gear length and OD for excessive wear.

Replace gears as a set if gears do not meet minimum specification.

30 3 -UN-22JAN90

MINIMUM ALLOWABLE GEAR SIZE

R39630

-UN-22JAN90

R39629

Gear OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43.231 mm (1.7020 in.)

Gear Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.805 mm (1.7639 in.)

RX,CTM730,4

-19-17FEB97

RX,CTM730,5

-19-17FEB97

NOTE: A measurable gear track area indicates over pressurization or worn bushings.

-UN-22JAN90

10. Inspect gear track and sealing areas (A) for pit marks and circular scratches. Replace housing if marks or scratches are excessive.

11. Inspect idler shaft (B) and bushing (C).

R39631

NEW PART SPECIFICATION Idler Shaft OD . . . . . . . . . . . . . . . . . . . . . . . . 12.319—12.335 mm (0.4850—0.4856 in.)

Bushing ID . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.129—16.179 mm (0.6350—0.6370 in.)

CTM7 (28FEB97)

-30-3

Radial Piston Pumps 280297

PN=127

Auxiliary Charge Pump-2000 and 3000 Series/Auxiliary Charge Pump 12. Measure end and side clearance between gear and housing.

MAXIMUM ALLOWABLE CLEARANCE

R39633

-UN-22JAN90

R39632

-UN-22JAN90

Side Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)

End Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.)

RX,CTM730,6

-19-17FEB97

RX,CTM730,7

-19-17FEB97

ASSEMBLE AUXILIARY CHARGE PUMP

-UN-22JAN90

IMPORTANT: DO NOT move 3000 Series hydraulic pump and inlet housing assembly with auxiliary charge pump removed. Doing so could dislodge key in end of pump shaft inside inlet housing causing hydraulic pump failure.

1. Coat gears with clean hydraulic oil and install gear set into charge pump housing.

R39634

30 4

2. Install new O-ring packing with a light coating of clean hydraulic oil.

CTM7 (28FEB97)

-30-4

Radial Piston Pumps 280297

PN=128

Auxiliary Charge Pump-2000 and 3000 Series/Auxiliary Charge Pump 3. Install new seal (A) inside control valve housing.

4. Remove excess oil film from surfaces (B) and carefully install auxiliary charge pump on control valve housing.

R39635

-UN-22JAN90

30 5

RX,CTM730,8

-19-17FEB97

RX,CTM730,9

-19-20FEB97

5. Tighten cap screws alternately to obtain a final torque: TORQUE SPECIFICATIONS

-UN-22JAN90

2000 Series: Long Cap Screws . . . . . . . . . . . . . . . . . . . . . 115 N·m (85 lb-ft) Short Cap Screws . . . . . . . . . . . . . . . . . . . . . 115 N·m (85 lb-ft)

R39496

3000 Series: Long Cap Screws . . . . . . . . . . . . . . . . . . . . . 200 N·m (150 lb-ft) Short Cap Screws . . . . . . . . . . . . . . . . . . . . . 115 N·m (85 lb-ft)

CTM7 (28FEB97)

-30-5

Radial Piston Pumps 280297

PN=129

Auxiliary Charge Pump-2000 and 3000 Series/Auxiliary Charge Pump

30 6

CTM7 (28FEB97)

-30-6

Radial Piston Pumps 280297

PN=130

Group 99

Dealer Fabricated Tools FABRICATED TOOLS Fabricated tools are tools identified by the factory as necessary for proper servicing that can be made at the dealership.

99 1

Use the information in this section to fabricate the tools required to perform service correctly.

RX,DFRW,INTRO -19-17OCT90

RW18921

-UN-22OCT91

DFRW52—PRESSURE COMPENSATOR VALVE INSTALLATION AND REMOVAL TOOL

A—“V” Groove Visible All Around B—1—2 mm x 45˚ Chamfer

C—10 mm (0.4 in.)

D—25.4 mm (1.0 in.)

E—229 mm (9.0 in.)

F—9/16 in. Stick

G—17 mm (0.67 in.)

Tool should be made from 9/16 in. nylon rod or other suitable material that will not splitter or flake causing damage to internal machined surfaces.

RX,DFRW52

CTM7 (28FEB97)

-99-1

-19-14OCT91

Radial Piston Pumps 280297

PN=131

Dealer Fabricated Tools

99 2

CTM7 (28FEB97)

-99-2

Radial Piston Pumps 280297

PN=132

Group 105

1000 Series (PR)-Operation and Tests HOW HYDRAULIC LINES ARE ROUTED

105 1 C

F

D

A B

G

D

-UN-21FEB97

H

RW16726

E

RW16726

A—Discharge Oil B—Inlet Oil C—Discharge Port

D—Inlet Ports E—Crankcase Pressure Port F—Drain Port

G—Serial Plate H—Destroke Port Plug (or Optional Manual Destroke)

NOTE: Applications vary. Some ports may not be used.

System pressure oil flows into hydraulic system from pump discharge port (C).

Charge pressure oil flows from hydraulic filter to inlet(s) (D).

Drain line (F) carries any oil which passes by pump shaft seal to sump.

RX,CTM7105,1

CTM7 (28FEB97)

-105-1

-19-20FEB97

Radial Piston Pumps 280297

PN=133

1000 Series (PR)-Operation and Tests/Pump Operation

HYDRAULIC PUMP OPERATION FULL STROKE

105 2

N

A

K F

D

J DESTROKE G

C E O

Q M L B

R

I

P

-19-24FEB97

H

S

RW16727

T

RW16727

A—Inlet Source B—High Pressure Outlet C—Crankcase Pressure Port D—Inlet Valve E—Discharge Valve F—Piston

G—Orifice H—Shaft I—Bearing Race J—Crankcase K—Pressure Compensator Valve

L—Crankcase Outlet Valve M—Pressure Compensator Adjusting Screw N—Manual Destroke Screw O—Sealing Ring

P—Oil Seal Q—Drain Passage R—Discharge Pressure Oil S—Crankcase Pressure Oil T—Inlet Pressure Oil

RX,CTM7105,2

CTM7 (28FEB97)

-105-2

-19-20FEB97

Radial Piston Pumps 280297

PN=134

1000 Series (PR)-Operation and Tests/Pump Operation The 1000 Series radial piston pump is a variable displacement pump. Inlet pressure oil (T) is supplied through inlets (A). The pump works with pressure compensator valve (K) to supply oil on demand to the components of the hydraulic system. When there is demand for oil in the system, the inlet pressure oil flows through the inlet valve (D) on the downward stroke of piston (F). As the piston moves outward, the inlet valve closes and the discharge valve (E) is forced open allowing the oil to flow out of the piston bore into the outlet gallery.

As the demand for oil in the system decreases, the pressure in the outlet gallery increases. The increasing pressure first closes the crankcase outlet valve (L). When the oil pressure reaches deadhead pressure, the pressure compensator valve (K) opens allowing high pressure oil to enter the crankcase (J).

The high pressure oil holds the pistons away from race and reducing pump displacement (output).

Enough stroke on the pistons will remain in order to maintain deadhead pressure.

When a hydraulic function is actuated, the pressure in the outlet gallery is decreased. Once the pressure decreases below deadhead pressure, the pressure compensator valve will close stopping the flow of oil into the crankcase. As the pressure drops lower, the crankcase outlet valve opens, dumps the high pressure oil, and allows the pump to go back into stroke.

The pump is also designed to allow oil to leak past the sealing ring (O) for lubrication purposes. The oil then flows through a drain passage (Q) back to sump.

The crankcase also contains a crankcase orifice (G).

The orifice allows oil to flow from the crankcase back to the inlet gallery at all times. Fresh oil then enters the crankcase for lubrication and cooling also allowing the pump to go back into stroke more gradually.

RX,CTM7105,3

CTM7 (28FEB97)

-105-3

-19-30NOV90

Radial Piston Pumps 280297

PN=135

105 3

1000 Series (PR)-Operation and Tests/Adjust Deadhead Pressure

ADJUST DEADHEAD (STANDBY) PRESSURE CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury.

Relieve pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Keep hands and body away from pin holes and nozzles which eject fluids under high pressure.

Use a piece of cardboard or paper to search for leaks. Do not use your hand.

If ANY fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with this type injury or gangrene may result.

-UN-23JAN90

NOTE: When operating or testing any hydraulic pump, it is good hydraulic systems practice to include a system relief valve set at 2070 kPa (20.7 bar) (300 psi) above deadhead pressure.

IMPORTANT: Adjusting screw should be set to a minimum depth to prevent excessive deadhead pressure at start up.

R40190

105 4

1. Install an adapter to port (A).

2. Connect a 0—34 500 kPa (0—345 bar) (0—5000 psi) gauge.

A—Test Port (E1) B—Pressure Compensator Adjusting Screw C—Lock Nut

NOTE: System pressures vary. Check applications or machine manual for proper deadhead pressure setting.

3. Turn adjusting screw (B) in to increase deadhead pressure.

4. Tighten lock nut (C) once deadhead pressure is set.

RX,CTM7105,4

CTM7 (28FEB97)

-105-4

-19-19FEB97

Radial Piston Pumps 280297

PN=136

Group 110

2000 Series (PR)-Operation and Tests HOW HYDRAULIC LINES ARE ROUTED K O C

M

D

110 1

K G

C

O

D

G

H

H

E

E

I R A I

L

B

P J

N

L RW16725

J

-UN-21FEB97

Q

RW16725

A—Discharge Oil B—Inlet Oil C—High Pressure Test Port (Top) (T1) D—Inlet Pressure Test Port (Bottom) (T2)

E—Inlet Pressure Sensing (V1) F—Inlet Pressure Sensing (V2) G—Drain Line (D1) H—Serial Plate

NOTE: Applications vary. Some ports may not be used.

Inlet pressure oil (B) flows from hydraulic filter to inlet(s) (K—N). Double bank pump may use a crossover pipe between primary and secondary housing inlet galleries (E) and (F) to equalize inlet gallery pressure. Inlet pressure may flow from pump

I—Manual Destroke Screw J—Electric Destroke Solenoid (Optional (C1-C2) K—Inlet Port (I1) L—Inlet Port (I2) M—Inlet Port (I3)

N—Inlet Port (I4) O—Discharge Port (S1) P—Discharge Port (S2) Q—Single Bank Pump R—Double Bank Pump

primary housing at (E) to provide sensing for hydraulic charge pump control valve. Discharge pressure oil (A) flows into hydraulic system from pump discharge ports (O) and (P).

Drain line (G) carries any oil which passes by pump shaft seal to sump.

RX,CTM7110,1

CTM7 (28FEB97)

-110-1

-19-20FEB97

Radial Piston Pumps 280297

PN=137

2000 Series (PR)-Operation and Tests/Pump Operation

HYDRAULIC PUMP OPERATION L

110 2

G

F

K E

A

M H I N -UN-24FEB97

O

J

P Q

A B

A—Inlet Source B—High Pressure Outlet C—Inlet Gallery D—Inlet Valve E—Discharge Valve

R

D

RW16722

RW16722

C

F—Piston G—Inlet Source H—Orifice I—Shaft J—Bearing Race

K—Crankcase L—Pressure Compensator Valve M—Crankcase Outlet Valve N—Pressure Compensator Housing

The 2000 Series radial piston pump is a variable displacement pump. Double banks are essentially two single bank pumps sharing a common shaft and pressure compensator. Designs vary slightly between serialized and non-serialized versions. Inlet oil (A) enters through inlet ports in the pump housing (O).

A common inlet gallery (C) in the pump housing provides oil to eight inlet valves (D). Pistons (F) radially surround an eccentric cam. The cam uses a bearing race (J) upon which the pistons ride. Behind each piston is a spring (some models have double springs) which pushes in and holds pistons against bearing race (J). As pump shaft (I) rotates, a low pressure cavity develops in the piston spring area during the downward stroke of piston. This low pressure allows inlet valve (D) to open, filling the piston cavity with oil. Inlet valves close at the end of inlet stroke of pistons. High pressure oil is developed as race pushes pistons outward. As pressure

O—Pump Housing P—Discharge Q—Crankcase Pressure Oil R—Inlet Pressure Oil

increases, discharge valve (E) opens allowing discharge pressure oil (P) to pass into the outlet gallery. At the end of stroke, discharge pressure oil in outlet gallery closes discharge valve (E). All discharge valves share a common outlet gallery in each pump housing. An orifice (H) is located between the crankcase and the inlet gallery. Any oil leakage past pistons is routed through orifice (H) to the inlet gallery. This flow allows for cooling and lubrication.

The pump is designed to provide “on demand” discharge pressure oil (P) regardless of flow requirements. As demand for oil decreases system pressure increases. This increased pressure closes crankcase outlet valve (M) and then opens pressure compensator valve (L) allowing high pressure oil to dump into crankcase (K) as deadhead pressure is reached. Increased pressure in the crankcase overcomes piston spring pressure and holds pistons (F) away from race (J), thereby destroking the pump.

RX,CTM7110,2

CTM7 (28FEB97)

-110-2

-19-20FEB97

Radial Piston Pumps 280297

PN=138

2000 Series (PR)-Operation and Tests/Pressure Compensator Valve Operation

PRESSURE COMPENSATOR VALVE OPERATION I

J

110 3

FULL STROKE

K

H L R

G M

S

F

N Q E

L

O

P

C

C A

RW16723

B RW16723

A—Pressure Compensator Adjusting Screw B—Spring C—Crankcase Outlet Valve D—From Pump Crankcase E—From Pump Inlet Gallery F—Inlet Pressure Test Port

G—Discharge Pressure Test Port H—Helmholz Resonator (Serialized Pumps) I—Pressure Sensing Pin (Serialized Pumps) J—To Pump Crankcase

There are two basic pressure compensator housing (P) designs. The one illustrated is for serialized pumps. A single spool crankcase outlet valve (C) is used on serialized pumps. Non-serialized pumps have a crankcase valve operating in a fixed sleeve. Both designs function the same. A crankcase design variation within both serialized and non-serialized pumps is provided in some pumps where improved performance under high load conditions is required. In non-serialized pumps, crankcase valve and outlet valve sleeve are replaced with a sleeve with a secondary orifice.

Crankcase outlet valve (C) in serialized pumps is replaced with a fixed valve also with a secondary orifice. Design variations allow a continuous flow of oil between pump crankcase and inlet gallery.

Slightly more horsepower is required at deadhead pressure.

K—Manual Destroke Screw L—Pressure Compensator Valve M—From Pump Outlet Gallery N—Destroke Plug or Optional Electric Destroke Solenoid

O—Spring P—Pressure Compensator Housing Q—Orifice R—Discharge Pressure S—Inlet Pressure

Valve housing (P) is connected to inlet (E), outlet gallery (M), and crankcase (D) and (J).

Compensator valve (L) working with the crankcase outlet (C) maintain discharge pressure under varying flow demands. Pressure oil enters at point (M) and flows to center section of compensator valve. At full stroke, illustrated, crankcase pressure is at inlet pressure. As demand for system oil decreases, discharge pressure will begin to increase, causing crankcase outlet valve (C) to close (move downward). This blocks the crankcase oil (D) from the inlet (E) except for any oil passing through the crankcase orifice (Q).

As system pressure approaches deadhead, compensator valve (L) opens (moves downward) allowing discharge pressure oil into the crankcase.

RX,CTM7110,3

CTM7 (28FEB97)

-19-21FEB97

D

-110-3

-19-20FEB97

Radial Piston Pumps 280297

PN=139

2000 Series (PR)-Operation and Tests/Pressure Compensator Valve Operation

I

J

DESTROKE

K

H

110 4

L R

G M

S

F

T

N Q E

L

O

P

C

C A

RW16724

B RW16724

A—Pressure Compensator Adjusting Screw B—Spring C—Crankcase Outlet Valve D—From Pump Crankcase E—From Pump Inlet Gallery F—Inlet Pressure Test Port G—Discharge Pressure Test Port

H—Helmholz Resonator (Serialized Pumps) I—Pressure Sensing Pin (Serialized Pumps) J—To Pump Crankcase K—Manual Destroke Screw L—Pressure Compensator Valve

As discharge pressure rises further, more oil enters the crankcase than can flow through orifice (Q).

Crankcase pressure increases to slightly higher than inlet pressure overcoming combined spring force on pump pistons. Pistons are then held away from pump shaft bearing race destroking pump. Pump shaft continues to rotate, but pistons do not move.

As demand for system oil increases, discharge pressure will decrease closing pressure compensator valve (L). Discharge Oil will no longer be routed to crankcase. Crankcase pressure begins to decrease as oil flows through crankcase orifice (Q). When discharge pressure decreases sufficiently, crankcase outlet valve (C) opens (moves upward) rapidly dumping pump crankcase.

M—From Pump Outlet Gallery N—Destroke Plug or Optional Electric Destroke Solenoid O—Spring

P—Pressure Compensator Housing Q—Orifice R—Discharge Pressure S—Inlet Pressure T—Low Pressure

Pump piston springs overcome decreased crankcase pressure and pistons again come in contact with shaft bearing race putting pump into stroke.

Helmholz resonator (I) on serialized pumps is a volume chamber that acts as a small attenuator. It reduces pressure spikes and dampens pressure compensator valve action. A manual destroke screw (K) is used to destroke pump without building deadhead pressure in hydraulic system. This reduces the load on the starting motor during cold weather starting and is also used in testing for hydraulic leaks.

Some pump models have a destroke plug (N). Using an optional electric destroke solenoid in place of plug (N) performs the same function as manual destroke screw (K).

RX,CTM7110,4

CTM7 (28FEB97)

-19-21FEB97

D

-110-4

-19-20FEB97

Radial Piston Pumps 280297

PN=140

2000 Series (PR)-Operation and Tests/Adjust Deadhead Pressure

ADJUST DEADHEAD (STANDBY) PRESSURE CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury.

Relieve pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Keep hands and body away from pinholes and nozzles which eject fluids under high pressure.

Use a piece of cardboard or paper to search for leaks. Do not use your hand.

110 5

If ANY fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with this type injury or gangrene may result.

-UN-22JAN90

NOTE: When operating or testing any hydraulic pump, it is good hydraulic systems practice to include a system relief valve set at 2070 kPa (20.7 bar) (300 psi) above deadhead pressure.

R39783

IMPORTANT: Adjusting screw should be set to a minimum depth to prevent excessive deadhead pressure at start up.

1. Install an adapter to high pressure test port (C).

2. Connect a 0—34 500 kPa (0—345 bar) (0—5000 psi) gauge.

NOTE: System pressures vary. Check applications or machine manual for proper deadhead pressure setting.

A—Pressure Compensator Adjusting Screw B—Inlet Pressure Test Port (T2) C—High Pressure Test Port (T1) D—Lock Nut

3. Turn adjusting screw (A) in to increase deadhead pressure.

4. Tighten lock nut (D) once deadhead pressure is set.

RX,CTM7110,5

CTM7 (28FEB97)

-110-5

-19-19FEB97

Radial Piston Pumps 280297

PN=141

2000 Series (PR)-Operation and Tests/Adjust Deadhead Pressure

110 6

CTM7 (28FEB97)

-110-6

Radial Piston Pumps 280297

PN=142

Group 115

3000 Series (HPR)-Operation and Tests HOW HYDRAULIC LINES ARE ROUTED G

C

E

G

M

115 1

C

M P

O N

N

K

K L

J

L

J I

H

D

A

F

D

RW16728

B

H

-UN-21FEB97

I

RW16728

A—Discharge Oil B—Inlet Oil C—Outlet Port (S1) D—Outlet Port (S2) E—Outlet Port (S3) F—Outlet Port (S4)

G—Inlet Port (I1) H—Inlet Port (I2) I—High Pressure Test Port (T1) J—Crankcase Pressure Test Port (T3)

K—Inlet Pressure Test Port (T2) L—Crankcase Access Port (C1) M—Drain Line (D1)

N—Serial Plate O—Pressure Compensator Valve Housing P—Load Sense Valve Housing

NOTE: Applications vary. Some ports may not be used.

Crankcase pressure may be sensed through port (L) for system applications.

Inlet oil (B) flow from hydraulic filter to inlet(s) (G) and (H).

Drain line (M) carries any oil which passes by pump shaft seal to sump.

Discharge oil (A) flows into hydraulic system from pump outlet ports (C—F).

RX,CTM7115,1

CTM7 (28FEB97)

-115-1

-19-20FEB97

Radial Piston Pumps 280297

PN=143

3000 Series (HPR)-Operation and Tests/Pump Operation

HYDRAULIC PUMP OPERATION

115 2

J K O L

U I T

N

A G F

H

D

M B

E

-UN-25FEB97

A

P Q R

C

RW16729

S RW16729

A—Inlet Source B—High Pressure Outlet C—Discharge Valve D—Piston E—Shaft F—Bearing Race

G—Inlet Valve H—Crankcase I—Orifice J—Pressure Compensator Adjusting Screw K—Spring

L—Pressure Compensator Valve M—Destroke Plug * N—Shuttle Valve O—Crankcase Relief Valve P—Discharge Pressure Oil

Q—Crankcase Pressure Oil R—Inlet Pressure Oil S—Pump Housing T—Inlet Housing U—Valve Housing

Unitized Design Single Bank Pump

* Optional Manual Destroke or Electric Destroke Solenoid

CTM7 (28FEB97)

RX,CTM7115,2

-115-2

-19-20FEB97

Radial Piston Pumps 280297

PN=144

3000 Series (HPR)-Operation and Tests/Pump Operation The 3000 Series radial piston pump is a variable displacement pump. Single and double bank versions operate the same to provide high pressure oil flow.

Double banks are essentially two single bank pumps sharing a common drive shaft and control valve.

Inlet oil (R) enters through inlet ports (A) in the inlet housing (T). A common inlet gallery in the housing provides oil to eight inlet valves (G) in pump housing (S). Pistons (D) radially surround an eccentric cam.

The cam uses a bearing race (F) upon which the pistons ride. Behind each piston is a spring which pushes in and holds pistons against the bearing race (F). As pump shaft (E) rotates a low pressure cavity develops in the piston spring area during downward stroke of piston. This low pressure allows inlet valve (G) to open filling the piston cavity with oil. Inlet valves close at the end of intake stroke of pistons.

High pressure oil is developed as race pushes

pistons outward. As pressure increases discharge valve (C) opens allowing discharge pressure oil (P) to pass into outlet gallery. At the end of stroke, discharge pressure oil in outlet gallery closes discharge valve (C). All discharge valves share a common outlet gallery in pump housing (S). An orifice (I) is located between the crankcase and the inlet gallery. Any oil leakage past the pistons is routed through orifice (I) to the inlet gallery. This flow allows for cooling and lubrication. Pressure compensated pumps (both older style non-unitized and newer style unitized designs) are designed to provide “on demand” discharge pressure oil (P) regardless of flow requirements. As demand for oil decreases, system pressure increases. Pressure compensator valve (L) then routes system oil into crankcase (H). Increased pressure in the crankcase overcomes piston spring pressure and hold pistons (D) away from race (F), thereby destroking the pump.

RX,CTM7115,3

CTM7 (28FEB97)

-115-3

-19-30NOV90

Radial Piston Pumps 280297

PN=145

115 3

3000 Series (HPR)-Operation and Tests/Pressure Compensator Operation

PRESSURE COMPENSATOR OPERATION—NON-UNITIZED DESIGN

115 4

A

Full Stroke B K

Q

L

C D E

M J

I N B

G

O

P -19-21FEB97

F

RW16720

H RW16720

A—Pressure Compensator Adjusting Screw B—Spring C—Spring Guide D—Pressure Compensator Valve

E—Sleeve F—Valve G—Spring H—Optional Manual Destroke or Electric Destroke Solenoid

I—Shuttle Valve J—Spring K—Discharge Pressure Oil L—Crankcase Pressure Oil M—Inlet Pressure Oil N—Pressure Compensator Valve in 1st Position

O—Pressure Compensator Valve in 2nd Position P—Pressure Compensator Valve in 3rd Position Q—Inlet Housing

Early Design

RX,CTM7115,4

CTM7 (28FEB97)

-115-4

-19-20FEB97

Radial Piston Pumps 280297

PN=146

3000 Series (HPR)-Operation and Tests/Pressure Compensator Operation The 3000 Series non-unitized designed inlet housing (Q) contains a pressure compensator valve as shown in this cross-section view. The pressure compensator valve (D) working within a fixed sleeve (E) maintains system pressure under varying flow demands. Valve movement is controlled on one end by outlet pressure (K) and on the other by force from spring (B) and crankcase pressure (L). Discharge pressure can be increased or decreased by changing the force on spring (B) using the pressure compensator adjusting screw (A). The pump may be manually destroked if equipped with an optional manual destroke screw or electric destroke solenoid (H). Shuttle valve (I) moves against spring (J) when manual destroke screw or electric solenoid are engaged. This allows discharge

pressure oil (K) to flow into inlet pressure oil (M), flow around the pressure compensator valve (D) and into the crankcase putting the pump into destroke. Shuttle valve (I) is only used to destroke the pump in conjunction with manual destroke or electric destroke solenoid.

The first pressure compensator valve position (N) is seen when pump is in FULL STROKE. In this position oil flowing through small orifice in crankcase is equal to the amount of oil flowing into crankcase via the pressure compensator valve (D). As demand for system oil decreases, system pressure will begin to increase. System pressure increase will move pressure compensator valve (D) toward spring (B).

RX,CTM7115,5

CTM7 (28FEB97)

-115-5

-19-30NOV90

Radial Piston Pumps 280297

PN=147

115 5

3000 Series (HPR)-Operation and Tests/Pressure Compensator Operation

A

115 6

Destroke

B

K

Q

L

C D

M

E

J

I N B

G

RW16721

A—Pressure Compensator Adjusting Screw B—Spring C—Spring Guide D—Pressure Compensator Valve

P

RW16721

H

O

-19-21FEB97

F

E—Sleeve F—Valve G—Spring H—Optional Manual Destroke or Electric Destroke Solenoid

I—Shuttle Valve J—Spring K—Discharge Pressure Oil L—Crankcase Pressure Oil M—Inlet Pressure Oil N—Pressure Compensator Valve in 1st Position

O—Pressure Compensator Valve in 2nd Position P—Pressure Compensator Valve in 3rd Position Q—Inlet Housing

Early Design

RX,CTM7115,6

CTM7 (28FEB97)

-115-6

-19-20FEB97

Radial Piston Pumps 280297

PN=148

3000 Series (HPR)-Operation and Tests/Pressure Compensator Operation When system pressure is reached, the pump DESTROKES. The pressure compensator valve will be in the second position (O). Discharge pressure oil is routed through valve (D) into crankcase cavity.

Crankcase pressure increases overcoming the combined spring force on the pump pistons. Pump pistons then are held away from pump shaft bearing race by increased crankcase pressure. The pump shaft continues to rotate, but pistons do not move.

As demand for system oil increases, discharge pressure will decrease moving pressure compensator valve (D) away from spring (B). System oil will no longer be routed to the crankcase. This will decrease crankcase pressure (L) as crankcase oil passes through the small orifice into inlet oil (M). Pump piston springs will overcome the decreased pressure in the crankcase and pistons will again come in contact with pump shaft bearing race.

QUICK DESTROKE OVERSHOOT is shown when the pressure compensator valve is in third position (P). During quick destroke, the pressure compensator valve moves far enough allowing discharge pressure oil to be routed to both crankcase and inlet oil and also allowing crankcase oil to feed into inlet oil. This limits high pressure spikes caused by discharge pressure oil being routed too rapidly into crankcase cavity.

A sudden demand for system oil will cause pressure compensator valve (D) to move rapidly downward.

Valve (F) and spring (G) acts like a shock absorber dampening the movement of the pressure compensator valve. Therefore, valve movement will not be influenced by periodic pressure spikes.

RX,CTM7115,7

CTM7 (28FEB97)

-115-7

-19-02JAN91

Radial Piston Pumps 280297

PN=149

115 7

3000 Series (HPR)-Operation and Tests/Pressure Compensator Operation

PRESSURE COMPENSATOR OPERATION—UNITIZED DESIGN

115 8

A

B

P

P G E

C

G N

E B M F

I

J L M

D

A—Pressure Compensator Adjusting Screw B—Pressure Compensator Spring(s) C—Spring Guide D—Pressure Compensator Valve

RW16730

O

E—Crankcase Relief Valve F—External Control Valve G—Spring H—Shuttle Valve I—Spring J—Discharge Pressure Oil

K—Crankcase Pressure Oil L—Inlet Pressure Oil M—Pressure Compensator Valve in 1st Position N—Pressure Compensator Valve in 2nd Position

O—Plug (or Optional Manual Destroke or Electric Solenoid) P—Valve Housing

RX,CTM7115,8

CTM7 (28FEB97)

-115-8

RW16730

-UN-21FEB97

H

-19-20FEB97

Radial Piston Pumps 280297

PN=150

3000 Series (HPR)-Operation and Tests/Pressure Compensator Operation The 3000 Series unitized designed pump provides a bolt-on control valve. The pressure compensator valve (D) controls the flow of the pump. Valve movement is controlled by discharge pressure oil (J) on one end of the valve and by inlet pressure oil (L) and force from spring (B) on the other end. Discharge pressure can be increased or decreased by changing the force on spring (B) using the pressure compensator adjusting screw (A). Shuttle valve (H) is used in conjunction with either a manual destroke screw or an electric destroke solenoid in place of plug (O). Valve (H) moves against crankcase relief valve (E) and spring (G) allowing discharge pressure oil to be dumped into crankcase thereby destroking the pump.

Pump is in FULL STROKE when pressure compensator valve (D) is in position (M) shown above. As demand for oil decreases, discharge pressure increases moving pressure compensator valve (D) toward spring (B).

Valve continues to move to position (N) dumping discharge pressure oil (J) into the crankcase, thereby increasing crankcase pressure. Crankcase pressure overcomes the combined spring force on the pump pistons. Pistons are then held away from the pump shaft bearing race and the pump is DESTROKED. The pump goes into QUICK DESTROKE when there is a sudden drop in demand for oil flow, creating a sudden increase in discharge pressure oil. Discharge pressure oil increases greatly allowing crankcase relief valve (E) to move against spring (G). This allows crankcase pressure oil (K) to dump into inlet pressure oil (L). This limits high pressure spikes caused by discharge pressure oil being too rapidly routed into crankcase cavity. An optional external control valve (F) is sometimes used in place of the crankcase relief valve (E). This provides for external load sensing control. This valve restricts the crankcase oil dumping into inlet.

RX,CTM7115,9

CTM7 (28FEB97)

-115-9

-19-02JAN91

Radial Piston Pumps 280297

PN=151

115 9

3000 Series (HPR)-Operation and Tests/Load Sense Operation

LOAD SENSE OPERATION—UNITIZED DESIGN

115 10

A

E F R

P

B

Q

C H

I

N

O

E

G

J K L -UN-21FEB97

M

RW16731

A—Pressure Compensator Adjusting Screw B—Pressure Compensator Spring(s) C—Spring Guide D—Pressure Compensator Valve

E—Crankcase Relief Valve F—Spring G—Load Sense Valve H—Spring I—Spring Guide J—Discharge Pressure Oil

K—Load Pressure Oil L—Crankcase Pressure Oil M—Inlet Pressure Oil N—Pressure Compensator Valve In 1st Position O—Pressure Compensator Valve in 2nd Position

RW16731

D

P—Load Sense Valve in 1st Position Q—Load Sense Valve in 2nd Position R—Valve Housing

RX,CTM7115,10 -19-19FEB97

CTM7 (28FEB97)

-115-10

Radial Piston Pumps 280297

PN=152

3000 Series (HPR)-Operation and Tests/Load Sense Operation The load sense unitized designed control valve provides a pressure compensator valve (D) and an additional load sense valve (G) each having the capability of decreasing or increasing the flow of the pump. Pump is in FULL STROKE when pressure compensator valve (D) and load sense valve (G) are in positions (N) and (P) shown above. As demand for oil flow decreases, discharge pressure oil increases moving both valves (D and G) towards springs (B) and (H). With both valves in position (O) and (Q) discharge pressure oil is routed into the crankcase increasing the crankcase pressure and limiting the movement of the pump pistons. Both the pressure compensator valve (D) and the load sense valve (G) are ported so they can decrease pump flow independently, but either valve can increase pump flow only if the other valve is in a position to permit the stroking function. This interaction allows the load sense valve to control the pump within the pressure

compensator valves pressure limit. The load sense valve maintains the pump discharge pressure (J) above the load sense pressure (K) by an amount proportional to the load sense spring (H) preload.

115 11

The crankcase relief valve (E) operates under two conditions. First, the valve moves against spring (F) when there is a sudden drop in demand for discharge oil flow. The pressure compensator valve dumps excess oil from the pump discharge into the crankcase. The crankcase relief valve in turn passes the oil back to the inlet. The second condition is when a directional valve is returned to neutral, allowing the load sense pressure (K) to drop. the load sense valve shifts to (Q) and decompresses the system into the crankcase. The relief valve quickly passes the oil into the inlet, allowing the pump discharge pressure to rapidly drop to the low standby pressure level.

RX,CTM7115,11 -19-02JAN91

CTM7 (28FEB97)

-115-11

Radial Piston Pumps 280297

PN=153

3000 Series (HPR)-Operation and Tests/Adjust Deadhead Pressure

ADJUST DEADHEAD (STANDBY) PRESSURE

If ANY fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with this type injury or gangrene may result.

R39624

-UN-22JAN90

CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury.

Relieve pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Keep hands and body away form pin holes and nozzles which eject fluids under high pressure.

Use a piece of cardboard or paper to search for leaks. Do not use your hand.

Non-Unitized Design

CAUTION: When operating or testing a non-unitized designed pump without a pressure compensator spring sleeve, a relief valve, set 2070 kPa (20.7 bar) (300 psi) above deadhead pressure, MUST BE used between pump discharge and nearest valve (or variable restriction) in system. Failure to do so can result in hydraulic component or line failure which may cause personal injury.

NOTE: When operating or testing any hydraulic pump, it is good hydraulic systems practice to include a system relief valve set at 2070 kPa (20.7 bar) (300 psi) above deadhead pressure.

-UN-23JAN90

IMPORTANT: Adjusting screw should be set to a minimum depth to prevent excessive deadhead pressure at start up.

1. Install a 14 mm adapter to high pressure test port (A).

R40193

115 12

2. Connect a 0—34 500 kPa (0—345 bar) (0—5000 psi) gauge.

Unitized Design

NOTE: System pressures vary. Check applications or machine manual for proper deadhead pressure setting.

3. Turn adjusting screw (C) in to increase deadhead pressure.

A—High Pressure Test Port (T1) B—Inlet Pressure Test Port (T2) C—Pressure Compensator Adjusting Screw D—Lock Nut E—Crankcase Pressure Test Port (T3)

4. Tighten lock nut (D) once deadhead pressure is set.

RX,CTM7115,12 -19-19FEB97

CTM7 (28FEB97)

-115-12

Radial Piston Pumps 280297

PN=154

Index Page

A Application chart Agricultural . . . . . . . . . .

Industrial . . . . . . . . . . .

OEM . . . . . . . . . . . . . .

Auxiliary charge pump . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. -10-9 -10-12 -10-15 . -30-2

C Charge pump .

Check end play 1000 Series .

2000 Series .

3000 Series .

. . . . . . . . . . . . . . . . . . . . -30-2 . . . . . . . . . . . . . . . . . . . . -15-7 . . . . . . . . . . . . . . . . . . . -20-14 . . . . . . . . . . . . . . . . . . . -25-15

Page

Operation and 1000 Series 2000 Series 3000 Series

tests . . . . . . . . . . . . . . . . . . . . -105-1 . . . . . . . . . . . . . . . . . . . . -110-1 . . . . . . . . . . . . . . . . . . . . -115-1

P Pump Displacement Identification .

Pump repair 1000 Series .

2000 Series .

3000 Series .

. . . . . . . . . . . . . . . . . . . . -10-1 . . . . . . . . . . . . . . . . . . . . -10-1 . . . . . . . . . . . . . . . . . . . . -15-6 . . . . . . . . . . . . . . . . . . . -20-13 . . . . . . . . . . . . . . . . . . . -25-14

S D Dealer fabricated tools .

Diagnosing malfunctions 1000 Series . . . . . . .

2000 Series . . . . . . .

3000 Series . . . . . . .

. . . . . . . . . . . . . . -99-1 . . . . . . . . . . . . . . -15-4 . . . . . . . . . . . . . . -20-7 . . . . . . . . . . . . . . -25-8

E End play 1000 Series . . . . . . . . . . . . . . . . . . . . . -15-7 2000 Series . . . . . . . . . . . . . . . . . . . . -20-14 3000 Series . . . . . . . . . . . . . . . . . . . . -25-15

F Fabricated tools . . . . . . . . . . . . . . . . . . . . -99-1

I Identification, pump . . . . . . . . . . . . . . . . . -10-1 Inch torque values . . . . . . . . . . . . . . . . . -10-17

M Metric torque values . . . . . . . . . . . . . . . . -10-16

O

Serial number plates . . . . . . . .

Series-1000 Adjust pressure . . . . . . . . .

Bearings (std) . . . . . . . . . . .

Crankcase outlet valve . . . . .

Discharge valve seats . . . . .

Discharge valves . . . . . . . .

End play . . . . . . . . . . . . . .

Filter . . . . . . . . . . . . . . . . .

Inlet valves . . . . . . . . . . . .

Operation and tests . . . . . . .

Piston assemblies . . . . . . . .

Pressure compensator valve .

Pump cover . . . . . . . . . . . .

Pump housing . . . . . . . . . .

Pump shaft . . . . . . . . . . . .

Quad ring . . . . . . . . . . . . .

Shaft seal . . . . . . . . . . . . .

Series-2000 Adjust crankcase outlet valve Adjust pressure . . . . . . . . .

Bearing cups . . . . . . . . . . .

Charge pump . . . . . . . . . . .

Crankcase outlet valve . . . . .

Discharge valve seats . . . . .

Discharge valves . . . . . . . .

End play . . . . . . . . . . . . . .

Fixed orifice . . . . . . . . . . . .

Inlet valves . . . . . . . . . . . .

Operation and tests . . . . . . .

Piston assemblies . . . . . . . .

Index-1

. . . . . . . . . -10-4 . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . .

-105-4 -15-12 -15-15 -15-14 -15-14 . -15-7 -15-16 -15-13 -105-1 . -15-6 -15-16 . -15-8 -15-11 . -15-8 -15-12 -15-12

. . . . . . . . . . . .

. . . . . . . . . . . .

. . . . . . . . . . . .

. . . . . . . . . . . .

. . . . . . . . . . . .

. . . . . . . . . . . .

. . . . . . . . . . . .

. . . . . . . . . . . .

-20-40 -110-5 -20-26 . -30-2 -20-37 -20-17 -20-15 -20-14 -20-42 -20-29 -110-1 -20-13

280297

PN=159

INDX 1

Index

INDX 2

Series-2000—Continued Pressure compensator valve . . .

Pump housing . . . . . . . . . . . .

Pump shaft . . . . . . . . . . . . . .

Shaft seal . . . . . . . . . . . . . . .

Series-3000 Adjust pressure . . . . . . . . . . .

Bearing cups . . . . . . . . . . . . .

Charge pump . . . . . . . . . . . . .

Compensator valve (non-unitized) Compensator valve (unitized) . .

Crankcase relief valve . . . . . . .

Discharge valve seats . . . . . . .

Discharge valves . . . . . . . . . .

End play . . . . . . . . . . . . . . . .

Inlet housing . . . . . . . . . . . . .

Inlet valves . . . . . . . . . . . . . .

Load sense . . . . . . . . . . . . . .

Operation and tests . . . . . . . . .

Piston assemblies . . . . . . . . . .

Pump housing . . . . . . . . . . . .

Pump shaft . . . . . . . . . . . . . .

Shaft seal . . . . . . . . . . . . . . .

Shuttle valve . . . . . . . . . . . . .

Valve housing . . . . . . . . . . . .

Specifications Auxiliary charge pump . . . . . . .

Basic . . . . . . . . . . . . . . . . . .

1000 Series . . . . . . . . . . . . . .

2000 Series . . . . . . . . . . . . . .

3000 Series . . . . . . . . . . . . . .

Page

. . . .

. . . .

. . . .

. . . .

. . . .

-20-30 -20-25 -20-18 -20-27

... . ... . ... . .. . ... . ... . ... . ... . ... . ... . ... . ... . ... . ... . ... . ... . ... . ... . ... .

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . .

-115-12 -25-23 . -30-2 -25-29 -25-35 -25-37 -25-26 -25-25 -25-15 -25-27 -25-26 -25-39 -115-1 -25-14 -25-23 -25-16 -25-23 -25-33 -25-34

. . . . .

. . . . .

. . . . .

. . . . .

. . . . .

. . . .

. . . . .

. . . . .

-30-1 -10-6 -15-3 -20-3 -25-3

T Tools, dealer fabricated . . . . . . . . . . . . . . . -99-1 Torque values Inch . . . . . . . . . . . . . . . . . . . . . . . . . -10-17 Metric . . . . . . . . . . . . . . . . . . . . . . . . -10-16

Index-2

280297

PN=160